Composite articles providing flame retardancy and noise reduction

ABSTRACT

A thermoplastic composite article comprising a porous core layer and an open cell skin disposed on a first surface of the core layer is described. The composite article comprises a noise reduction coefficient of at least 0.5 as tested by ASTM C423-17 and a flame spread index of less than 25 and a smoke development index of less than 150 as tested by ASTM E84 dated 2009.

RELATED APPLICATIONS

This application is related to, and claims priority to and the benefitof, each of U.S. Provisional Application No. 62/614,038 filed on Jan. 5,2018 and U.S. Provisional Application No. 62/638,859 filed on Mar. 5,2018, the entire disclosure of each of which is hereby incorporatedherein by reference.

TECHNOLOGICAL FIELD

Certain examples described herein are directed to composite articlesthat provide both flame retardancy and noise reduction.

BACKGROUND

Composite materials have broad applications in different industries,such as building and construction, automotive, and recreationalvehicles. To be used in these industries, the composite materials oftenneed to meet certain performance characteristics.

SUMMARY

Certain aspects, embodiments, configurations and examples of lightweightreinforced thermoplastic (LWRT) composite articles that can provide bothflame retardancy and noise reduction are described. While certainconfigurations are described as including certain components, thecomponents can be rearranged, substituted or otherwise altered toprovide articles with desired performance characteristics. In addition,other components, layers and material can be used on, in or with theillustrative components described herein.

In a first aspect, a thermoplastic composite article comprising a porouscore layer comprising a web of open celled structures comprising arandom arrangement of a plurality of reinforcing fibers held together bya thermoplastic material, wherein the porous core layer comprises aflame retardant agent and a basis weight of at least 2500 grams persquare meter (gsm), e.g., at least 2800 gsm, is provided. In someexamples, the composite article also comprises an open cell skindisposed on a first surface of the porous core layer, wherein thecomposite article comprises a noise reduction coefficient of at least0.5 as tested by ASTM C423-17, and wherein the composite articlecomprises a flame spread index of less than 25 and a smoke developmentindex of less than 150 as tested by ASTM E84 dated 2009.

In certain embodiments, the flame retardant agent comprises expandablegraphite particles. In some examples, the open cell skin comprises aperforated film with an open surface area of at least 10%, and whereinthe composite article comprises a noise reduction coefficient of atleast 0.85 as tested by ASTM C423-17.

In other embodiments, the flame retardant agent comprises magnesiumhydroxide. In some instances, the open cell skin comprises a perforatedfilm with an open surface area of at least 10%, and wherein thecomposite article comprises a noise reduction coefficient of at least0.85 as tested by ASTM C423-17.

In some examples, the thermoplastic material comprises a polyolefinresin. In other examples, the plurality of reinforcing fibers compriseglass fibers. In some embodiments, the composite article comprises adecorative layer disposed on a second surface of the porous core layer.

In other examples, the composite article comprises a closed cell skindisposed on a second surface of the porous core layer. In some examples,the composite article comprises a decorative layer disposed on theclosed cell skin.

In another aspect, a ceiling tile comprises a porous core layer and anopen cell skin disposed on the porous core layer. For example, theceiling tile can comprise a porous core layer comprising a web of opencelled structures comprising a random arrangement of a plurality ofreinforcing fibers held together by a thermoplastic material, whereinthe porous core layer comprises a flame retardant agent and a basisweight of at least 2500 gsm, e.g., at least 2800 gsm. The ceiling tilemay also comprise an open cell skin disposed on a first surface of theporous core layer, wherein the ceiling tile comprises a noise reductioncoefficient of at least 0.5 as tested by ASTM C423-17, and wherein theceiling tile comprises a flame spread index of less than 25 and a smokedevelopment index of less than 150 as tested by ASTM E84 dated 2009.

In certain embodiments, the open cell skin comprises an open surfacearea of at least 10%, and wherein the ceiling tile comprises a noisereduction coefficient of at least 0.85 as tested by ASTM C423-17. Inother embodiments, the ceiling tile further comprises a porousdecorative layer disposed on the open cell skin. In some examples, theflame retardant agent comprises expandable graphite particles ormagnesium hydroxide or both. In certain examples, the open cell skincomprises a perforated film with an open surface area of at least 10%,and wherein the ceiling tile panel comprises a noise reductioncoefficient of at least 0.85 as tested by ASTM C423-17. In someembodiments, the ceiling tile comprises a closed cell skin disposed on asecond surface of the porous core layer. In certain instances, the flameretardant agent is homogeneously dispersed in the porous core layer. Insome examples, the thermoplastic material comprises a polyolefin resin.In certain examples, the plurality of reinforcing fibers comprise glassfibers or mineral fibers or both. In some embodiments, the porous corelayer further comprises a clay.

In another aspect, a cubicle wall panel sized and arranged to couple toanother cubicle wall panel is described. For example, the cubicle wallpanel may comprise a porous core layer comprising a web of open celledstructures comprising a random arrangement of a plurality of reinforcingfibers held together by a thermoplastic material, wherein the porouscore layer comprises a flame retardant agent and a basis weight of atleast 2500 gsm. e.g., at least 2800 gsm. The cubicle wall panel may alsocomprise an open cell skin disposed on a first surface of the porouscore layer, wherein the cubicle wall panel comprises a noise reductioncoefficient of at least 0.5 as tested by ASTM C423-17, and wherein thecubicle wall panel comprises a flame spread index of less than 25 and asmoke development index of less than 150 as tested by ASTM E84 dated2009.

In some examples, the open cell skin comprises an open surface area ofat least 10%, and wherein the cubicle wall panel comprises a noisereduction coefficient of at least 0.85 as tested by ASTM C423-17. Inother examples, the cubicle wall panel comprises a porous decorativelayer disposed on the open cell skin. In some examples, the flameretardant agent comprises expandable graphite particles or magnesiumhydroxide or both. In further examples, the open cell skin comprises aperforated film with an open surface area of at least 10%, and whereinthe cubicle wall panel comprises a noise reduction coefficient of atleast 0.85 as tested by ASTM C423-17. In some instances, the cubiclewall panel comprises a closed cell skin disposed on a second surface ofthe porous core layer. In other examples, the flame retardant agent ishomogeneously dispersed in the porous core layer. In some embodiments,the thermoplastic material comprises a polyolefin resin. In certainexamples, the plurality of reinforcing fibers comprise glass fibers ormineral fibers or both. In some instances, the porous core layer furthercomprises a clay.

In an additional aspect, a structural panel comprises a porous corelayer, an open cell skin and a structural substrate coupled to theporous core layer. The porous core layer can comprise a web of opencelled structures comprising a random arrangement of a plurality ofreinforcing fibers held together by a thermoplastic material, whereinthe porous core layer comprises a flame retardant agent and a basisweight of at least 2500 gsm, e.g., at least 2800 gsm. The open cell skincan be coupled to a first surface of the porous core layer. Thestructural substrate can be coupled to a second surface of the porouscore layer, wherein the structural panel comprises a flame spread indexof less than 25 and a smoke development index of less than 150 as testedby ASTM E84 dated 2009, and wherein the structural panel provides anoise reduction coefficient of at least 0.85 as tested by ASTM C423-17.

In certain embodiments, the structural substrate comprises a plywoodpanel, a gypsum board, a wood tile, a ceramic tile, a metal tile, a woodpanel, a concrete panel, a concrete board or a brick. In otherembodiments, the open cell skin comprises an open surface area of atleast 10%, and wherein the structural panel comprises a noise reductioncoefficient of at least 0.85 as tested by ASTM C423-17. In someexamples, the structural panel comprises a porous decorative layerdisposed on the open cell skin. In certain examples, the flame retardantagent comprises expandable graphite particles or magnesium hydroxide orboth. In some examples, the open cell skin comprises a perforated filmwith an open surface area of at least 10%, and wherein the structuralpanel comprises a noise reduction coefficient of at least 0.85 as testedby ASTM C423-17. In other examples, the structural panel comprises aclosed cell skin disposed on a second surface of the porous core layer.In some embodiments, the flame retardant agent is homogeneouslydispersed in the porous core layer. In certain examples, thethermoplastic material comprises a polyolefin resin and the plurality ofreinforcing fibers comprise glass fibers or mineral fibers or both. Insome examples, the structural panel comprises a second structural panelcoupled to the open cell skin, wherein the second structural panel is aporous structural panel.

In another aspect, a wall panel comprises a porous core layer, an opencell skin and a wall substrate. The porous core layer comprises a web ofopen celled structures comprising a random arrangement of a plurality ofreinforcing fibers held together by a thermoplastic material, whereinthe porous core layer comprises a flame retardant agent and a basisweight of at least 2500 gsm, e.g., at least 2800 gsm. The open cell skincan be coupled to a first surface of the porous core layer. The wallsubstrate can be coupled to a second surface of the porous core layerand configured to support the porous core layer when the wall panel iscoupled to a wall surface, wherein the wall panel comprises a flamespread index of less than 25 and a smoke development index of less than150 as tested by ASTM E84 dated 2009, and wherein the wall panelcomprises a sound absorption coefficient of at least 0.5 as tested byASTM C423-17.

In some examples, the wall substrate is cellulose free. In otherexamples, the open cell skin comprises an open surface area of at least10%, and wherein the wall panel comprises a noise reduction coefficientof at least 0.85 as tested by ASTM C423-17. In some examples, the wallpanel comprises a porous decorative layer disposed on the open cellskin. In certain instances, the flame retardant agent comprisesexpandable graphite particles or magnesium hydroxide or both. In someexamples, the open cell skin comprises a perforated film with an opensurface area of at least 10%, and wherein the wall panel comprises anoise reduction coefficient of at least 0.5 as tested by ASTM C423-17.In other embodiments, the wall panel comprises a closed cell skindisposed on a second surface of the porous core layer. In some examples,the flame retardant agent is homogeneously dispersed in the porous corelayer. In certain examples, the thermoplastic material comprises apolyolefin resin and the plurality of reinforcing fibers comprise glassfibers or mineral fibers or both. In some embodiments, the wall panelcomprises a second wall panel coupled to the open cell skin, wherein thesecond wall panel is a porous wall panel.

In an additional aspect, a vinyl siding panel comprises a flameretardant and noise reducing layer and a vinyl substrate. In someexamples, the flame retardant and noise reducing layer comprises aporous core layer comprising a web of open celled structures comprisinga random arrangement of a plurality of reinforcing fibers held togetherby a thermoplastic material, wherein the porous core layer comprises aflame retardant agent and a basis weight of at least 2500 gsm, e.g., atleast 2800 gsm, and an open cell skin coupled to a first surface of theporous core layer, wherein the flame retardant layer comprises a flamespread index of less than 25 and a smoke development index of less than150 as tested by ASTM E84 dated 2009, and wherein the flame retardantlayer comprises a noise reduction coefficient of at least 0.5 as testedby ASTM C423-17. The vinyl substrate can be coupled to a first surfaceof the flame retardant and noise reducing layer and configured to coupleto a non-horizontal surface of a building to retain the vinyl sidingpanel to the non-horizontal surface of a building.

In certain examples, the vinyl siding panel comprises a weather barriercoupled to a second surface of the flame retardant and noise reducinglayer. In some examples, the vinyl substrate comprises a nailing flange.In other examples, the open cell skin comprises an open surface area ofat least 10%, and wherein the vinyl siding comprises a noise reductioncoefficient of at least 0.85 as tested by ASTM C423-17. In someexamples, the flame retardant agent comprises expandable graphiteparticles or magnesium hydroxide or both. In certain embodiments, theopen cell skin comprises a perforated film with an open surface area ofat least 10%, and wherein the vinyl siding panel comprises a noisereduction coefficient of at least 0.85 as tested by ASTM C423-17. Insome examples, the vinyl siding panel comprises a closed cell skindisposed on a second surface of the porous core layer. In otherexamples, the flame retardant agent is homogeneously dispersed in theporous core layer. In some instances, the thermoplastic materialcomprises a polyolefin resin and the plurality of reinforcing fiberscomprise glass fibers or mineral fibers or both. In some embodiments,the vinyl siding panel comprises a second vinyl siding panel comprisinga second flame retardant and noise reducing layer coupled to a secondvinyl substrate, wherein the flame retardant and noise reducing layer isconfigured to lock into the second flame retardant and noise reducinglayer when the vinyl substrate is coupled to the second vinyl substrate.

In another aspect, a roofing panel comprises a flame retardant and noisereducing layer and a roofing substrate. The a flame retardant and noisereducing layer comprises a porous core layer comprising a web of opencelled structures comprising a random arrangement of a plurality ofreinforcing fibers held together by a thermoplastic material, whereinthe porous core layer comprises a flame retardant agent and a basisweight of at least 2500 gsm, e.g., at least 2800 gsm, and an open cellskin coupled to a first surface of the porous core layer, wherein theflame retardant and noise reducing layer comprises a flame spread indexof less than 25 and a smoke development index of less than 150 as testedby ASTM E84 dated 2009, and wherein the flame retardant and noisereducing layer comprises a noise reduction coefficient of at least 0.5as tested by ASTM C423-17. The roofing substrate can be coupled to afirst surface of the flame retardant and noise reducing layer andconfigured to couple to a roof of a dwelling to retain the roofing panelto the roof.

In certain embodiments, the roofing panel comprises a weather barriercoupled to a second surface of the flame retardant and noise reducinglayer. In some examples, the roofing substrate comprises acellulose-based material. In other examples, the open cell skincomprises an open surface area of at least 10%, and wherein the roofingpanel comprises a noise reduction coefficient of at least 0.85 as testedby ASTM C423-17. In some embodiments, the flame retardant agentcomprises expandable graphite particles or magnesium hydroxide or both.In some examples, the open cell skin comprises a perforated film with anopen surface area of at least 10%, and wherein the roofing panelcomprises a noise reduction coefficient of at least 0.85 as tested byASTM C423-17. In some examples, the roofing panel comprises a closedcell skin disposed on a second surface of the porous core layer. Incertain embodiments, the flame retardant agent is homogeneouslydispersed in the porous core layer. In some examples, the thermoplasticmaterial comprises a polyolefin resin and the plurality of reinforcingfibers comprise glass fibers or mineral fibers or both. In someembodiments, the roofing panel comprises a second roofing panelcomprising a second flame retardant and noise reducing layer coupled toa second roofing substrate, wherein the flame retardant and noisereducing layer is configured to lock into the second flame retardant andnoise reducing layer when the roofing substrate is positioned to overlapthe second roofing substrate.

In an additional aspect, a roofing shingle comprises a flame retardantand noise reducing layer and a weatherproof roofing shingle substrate.In some examples, flame retardant and noise reducing layer comprises aporous core layer comprising a web of open celled structures comprisinga random arrangement of a plurality of reinforcing fibers held togetherby a thermoplastic material, wherein the porous core layer comprises aflame retardant agent and a basis weight of at least 2500 gsm, e.g., atleast 2800 gsm, and an open cell skin coupled to a first surface of theporous core layer, wherein the flame retardant and noise reducing layercomprises a flame spread index of less than 25 and a smoke developmentindex of less than 150 as tested by ASTM E84 dated 2009, and wherein theflame retardant and noise reducing layer comprises a noise reductioncoefficient of at least 0.5 as tested by ASTM C423-17. The weatherproofroofing shingle substrate can be coupled to a first surface of the flameretardant and noise reducing layer and configured to couple to a roofingpanel of a building to provide a weatherproof, flame retardant and noisereducing roofing shingle over the roofing panel.

In some examples, the roofing shingle comprises a weather barriercoupled to a second surface of the flame retardant and noise reducinglayer. In some examples, the roofing shingle comprises asphalt. In otherexamples, the open cell skin comprises an open surface area of at least10%, and wherein the roofing shingle comprises a noise reductioncoefficient of at least 0.85 as tested by ASTM C423-17. In certainexamples, the flame retardant agent comprises expandable graphiteparticles or magnesium hydroxide or both. In some embodiments, the opencell skin comprises a perforated film with an open surface area of atleast 10%, and wherein the roofing shingle comprises a noise reductioncoefficient of at least 0.85 as tested by ASTM C423-17. In someexamples, the roofing shingle comprises a closed cell skin disposed on asecond surface of the porous core layer. In certain embodiments, theflame retardant agent is homogeneously dispersed in the porous corelayer. In certain examples, the thermoplastic material comprises apolyolefin resin and the plurality of reinforcing fibers comprise glassfibers or mineral fibers or both. In other examples, the roofing shinglecomprises a second roofing shingle comprising a second flame retardantand noise reducing layer coupled to a second weatherproof roof shingle,wherein the flame retardant and noise reducing layer is configured tolock into the second flame retardant and noise reducing layer when theweatherproof roofing shingle is positioned to overlap the secondweatherproof roof shingle.

In another aspect, a recreational vehicle interior panel comprises aflame retardant and sound reducing layer and an interior wall substrate.The flame retardant and sound reducing layer comprises a porous corelayer comprising a web of open celled structures comprising a randomarrangement of a plurality of reinforcing fibers held together by athermoplastic material, wherein the porous core layer comprises a flameretardant agent and a basis weight of at least 2500 gsm, e.g., at least2800 gsm, and an open cell skin coupled to a first surface of the porouscore layer. The interior wall substrate can be coupled to a secondsurface of the porous core layer, wherein the recreational vehicleinterior panel comprises a flame spread index of less than 25 and asmoke development index of less than 150 as tested by ASTM E84 dated2009, and wherein the recreational interior vehicle panel comprises anoise reduction coefficient of at least 0.5 as tested by ASTM C423-17.

In some examples, the interior wall substrate is configured as adecorative layer. In other examples, the open cell skin comprises anopen surface area of at least 10%, and wherein the recreational vehicleinterior panel comprises a noise reduction coefficient of at least 0.85as tested by ASTM C423-17. In some embodiments, the flame retardantagent comprises expandable graphite particles or magnesium hydroxide orboth. In certain examples, the open cell skin comprises a perforatedfilm with an open surface area of at least 10%, and wherein therecreational vehicle interior panel comprises a noise reductioncoefficient of at least 0.85 as tested by ASTM C423-17. In otherexamples, the recreational vehicle interior panel comprises a closedcell skin disposed on a second surface of the porous core layer. Inother examples, the flame retardant agent is homogeneously dispersed inthe porous core layer. In some examples, the thermoplastic materialcomprises a polyolefin resin and the plurality of reinforcing fiberscomprise glass fibers or mineral fibers or both. In other examples, therecreational vehicle interior panel comprises a second recreationalvehicle interior panel comprising a second flame retardant and noisereducing layer coupled to a second interior wall substrate, wherein theflame retardant and noise reducing layer is configured to lock into thesecond flame retardant and noise reducing layer when the interior wallsubstrate is positioned to vertically overlap the second interior wallsubstrate at a first side of the recreational vehicle interior panel. Inadditional examples, the recreational vehicle interior panel comprises athird recreational vehicle interior panel comprising a third flameretardant and noise reducing layer coupled to a third interior wallsubstrate, wherein the flame retardant and noise reducing layer isconfigured to lock into the third flame retardant and noise reducinglayer when the interior wall substrate is positioned to verticallyoverlap the third interior wall substrate at a second side of therecreational vehicle interior panel.

In an additional aspect, a recreational vehicle exterior panel comprisesa flame retardant and sound reducing layer and a weatherproof exteriorwall substrate. The flame retardant and sound reducing layer comprises aporous core layer comprising a web of open celled structures comprisinga random arrangement of a plurality of reinforcing fibers held togetherby a thermoplastic material, wherein the porous core layer comprises aflame retardant agent and a basis weight of at least 2500 gsm, e.g., atleast 2800 gsm, and an open cell skin coupled to a first surface of theporous core layer. The weatherproof exterior wall substrate can becoupled to a second surface of the porous core layer, wherein therecreational vehicle exterior panel comprises a flame spread index ofless than 25 and a smoke development index of less than 150 as tested byASTM E84 dated 2009, and wherein the recreational exterior vehicle panelcomprises a noise reduction coefficient of at least 0.5 as tested byASTM C423-17.

In some examples, the exterior wall substrate comprises glass fibers oris configured as a metal panel. In other examples, the open cell skincomprises a perforated film with an open surface area of at least 10%,and wherein the recreational vehicle exterior panel comprises a noisereduction coefficient of at least 0.85 as tested by ASTM C423-17. Inadditional examples, the flame retardant agent comprises expandablegraphite particles or magnesium hydroxide or both. In other embodiments,the open cell skin comprises a perforated film with an open surface areaof at least 10%, and wherein the recreational vehicle exterior panelcomprises a noise reduction coefficient of at least 0.85 as tested byASTM C423-17. In some examples, the recreational vehicle exterior panelcomprises a closed cell skin disposed on a second surface of the porouscore layer. In other examples, the flame retardant agent ishomogeneously dispersed in the porous core layer. In some embodiments,the thermoplastic material comprises a polyolefin resin and theplurality of reinforcing fibers comprise glass fibers or mineral fibersor both. In other examples, the recreational vehicle exterior panelcomprises a second recreational vehicle exterior panel comprising asecond flame retardant and noise reducing layer coupled to a secondexterior wall substrate, wherein the flame retardant and noise reducinglayer is configured to lock into the second flame retardant and noisereducing layer when the exterior wall substrate is positioned to overlapthe second exterior wall substrate at a first side of the recreationalvehicle exterior panel. In some examples, the recreational vehicleexterior panel comprises a third recreational vehicle exterior panelcomprising a third flame retardant and noise reducing layer coupled to athird exterior wall substrate, wherein the flame retardant and noisereducing layer is configured to lock into the third flame retardant andnoise reducing layer when the exterior wall substrate is positioned tooverlap the third exterior wall substrate at a second side of therecreational vehicle exterior panel.

In another aspect, an interior building panel comprising a two- orthree-dimensional feature is provided. In some examples, the interiorbuilding panel comprises a porous core layer comprising a web of opencelled structures comprising a random arrangement of a plurality ofreinforcing fibers held together by a thermoplastic material, whereinthe porous core layer comprises a flame retardant agent and a basisweight of at least 2500 gsm, e.g., at least 2800 gsm, and an open cellskin disposed on a first surface of the porous core layer, wherein theinterior building panel comprising the two- or three-dimensional featurecomprises a noise reduction coefficient of at least 0.5 as tested byASTM C423-17, and wherein the interior building panel comprising thetwo- or three-dimensional feature comprises a flame spread index of lessthan 25 and a smoke development index of less than 150 as tested by ASTME84 dated 2009.

In an additional aspect, an interior trim article is described. Theinterior trim may comprise, for example, a flame retardant and noisereducing layer and an interior trim substrate. The flame retardant andnoise reducing layer comprises a porous core layer comprising a web ofopen celled structures comprising a random arrangement of a plurality ofreinforcing fibers held together by a thermoplastic material, whereinthe porous core layer comprises a flame retardant agent and a basisweight of at least 2500 gsm, e.g., at least 2800 gsm, and an open cellskin disposed on a first surface of the porous core layer, wherein theflame retardant and noise reducing layer comprises a noise reductioncoefficient of at least 0.5 as tested by ASTM C423-17, and wherein theflame retardant and noise reducing layer comprises a flame spread indexof less than 25 and a smoke development index of less than 150 as testedby ASTM E84 dated 2009. The interior trim substrate can be coupled to afirst surface of the flame retardant and noise reducing layer. Theinterior trim can be, for example, base molding, crown molding, doormolding, chair rail, window molding or other interior trim articles.

Additional aspects, configurations, embodiments, examples and featuresare described in more detail below.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Certain illustrative configurations of composite articles are describedwith reference to the figures in which:

FIG. 1 is an illustration of a composite article comprising a prepreg orcore layer coupled to an open cell skin on one surface, in accordancewith certain configurations;

FIG. 2 is an illustration of a composite article comprising a prepreg orcore layer coupled to an open cell skin on one surface where differentareas of the open cell skin comprise a different porosity orpermeability, in accordance with certain configurations;

FIG. 3 is an illustration of a composite article comprising a prepreg orcore layer coupled to an open cell skin on one surface and a second opencell skin coupled to the open cell skin, in accordance with certainconfigurations;

FIG. 4A is an illustration of a composite article comprising a prepregor core layer coupled to an open cell skin on one surface and includinga surface layer disposed on the open cell skin, in accordance withcertain examples;

FIG. 4B is an illustration of a composite article comprising a prepregor core layer coupled to an open cell skin on one surface and includinga surface layer disposed on the open cell skin and another surface layerdisposed on the prepreg or core layer, in accordance with certainexamples;

FIG. 5 is an illustration of a composite article comprising a prepreg orcore layer coupled to an open cell skin on one surface and coupled to aclosed cell skin on an opposite surface, in accordance with certainembodiments;

FIG. 6 is an illustration of a composite article comprising a prepreg orcore layer coupled to an open cell skin on one surface and a surfacelayer coupled to the prepreg or core layer on an opposite surface, inaccordance with some configurations;

FIG. 7 is an illustration of a composite article comprising a prepreg orcore layer coupled to an open cell skin on one surface, coupled to aclosed cell skin on an opposite surface and where the open cell skin iscoupled to a surface layer, in accordance with certain embodiments;

FIG. 8 is an illustration of a composite article comprising a firstprepreg or core layer coupled to a second prepreg or core layer throughan open cell skin, in accordance with certain examples;

FIG. 9 is an illustration of a composite article comprising a firstprepreg or core layer coupled to a second prepreg or core layer throughan open cell skin and comprising another open cell skin coupled to oneof the prepreg or core layers, in accordance with certain examples;

FIG. 10 is an illustration of a composite article comprising a firstprepreg or core layer coupled to a second prepreg or core layer throughan open cell skin and comprises a closed cell skin coupled to one of theprepreg or core layers, in accordance with certain embodiments;

FIG. 11 is an illustration showing ceiling tiles where one of theceiling tiles comprises a LWRT article as described herein, inaccordance with certain examples;

FIG. 12 is an illustration cubicle panels where one of the panelscomprises a LWRT article as described herein, in accordance with certainexamples;

FIG. 13A is an illustration of a structural panel comprising a LWRTarticle as described herein, and FIG. 13B is an illustration of astructural panel comprising a LWRT article coupled to a structuralsubstrate, in accordance with certain embodiments;

FIG. 14 is an illustration of wall board comprising a LWRT article asdescribed herein, in accordance with certain examples;

FIG. 15 is an illustration of building siding comprising a LWRT articleas described herein, in accordance with certain embodiments;

FIG. 16 is an illustration of a roofing panel comprising a LWRT articleas described herein, in accordance with certain embodiments;

FIG. 17 is an illustration of a roofing shingle comprising a LWRTarticle as described herein, in accordance with certain embodiments;

FIG. 18 is an illustration of an interior recreational vehicle wallcomprising a LWRT article as described herein, in accordance withcertain embodiments;

FIG. 19 is an illustration of an exterior recreational vehicle wallcomprising a LWRT article as described herein, in accordance withcertain embodiments;

FIG. 20 is an illustration of an interior panel comprising a LWRTarticle comprising a two-dimensional feature, in accordance with certainexamples;

FIG. 21 is an illustration of interior trim comprising a LWRT articlecomprising a two-dimensional feature, in accordance with certainconfigurations;

FIG. 22 is a graph showing sound absorption results for certain testedmaterials, in accordance with certain examples;

FIG. 23 is a graph showing acoustic properties measured on Sample A1 andSample A2, in accordance with certain configurations;

FIG. 24 is a graph showing sound absorption performance of Control Bsample, in accordance with certain examples;

FIG. 25 is a graph showing sound absorption performance of Sample B3, inaccordance with certain examples;

FIG. 26A is a photograph showing a top side of a specimen afterflammability testing, in accordance with some examples;

FIG. 26B is a photograph showing a bottom side of a specimen afterflammability testing, in accordance with some examples;

FIG. 27 is a bar graph comparing flexural strength measurements ofdifferent samples, in accordance with some examples; and

FIG. 28 is another bar graph comparing flexural strength measurements ofdifferent samples, in accordance with some examples.

It will be recognized by the person of ordinary skill in the art, giventhe benefit of this disclosure, that the illustrative representationsshown in FIGS. 1-21 are provided for convenience and to facilitate abetter understanding. The exact shape, length, width, thickness,geometry and overall orientation of the components in the figures mayvary depending on the intended use and desired properties.

DETAILED DESCRIPTION

Examples of some configurations of composite articles are described thatmay comprise two or more layers coupled to each other. While variouslayers are shown in the figures and are described below, the thickness,size and geometry of the different layers need not be the same and maybe other thicknesses, size and geometries than those shown in thefigures. Further, the exact arrangement or layering of the componentscan be altered or intermediate layers may be present between theillustrative layers shown in the figures.

In certain embodiments, the articles described herein generally comprisea prepreg or core layer coupled to another layer. A prepreg can be anon-fully formed core layer and may comprise materials that areprocessed to form a final core layer. For example, the prepreg maycomprise thermoplastic materials in combination with reinforcing fibersbut may not be fully formed or may be present in a softened state byapplication of heat. The prepreg may be pressed, compressed or moldedinto a desired shape to provide a core layer. The other layers coupledto the prepreg layer may be added prior to fully forming the core orafter fully forming the core. The other layers can be coupled to theprepreg or core layer using an adhesive or, in some instances, theprepreg or core layer may be directly coupled to other layers withoutthe use of any adhesive material between the prepreg or core layer andthe other layers.

In certain examples, the prepregs or core layers can be used in alightweight reinforced thermoplastic (LWRT) article. LWRT's can providecertain desirable attributes including, but not limited to, highstiffness-to-weight ratio, low part weight, simple and low-cost partforming process, low coefficient of thermal expansion, recyclability,and others. LWRT have broad applications in the automotive industry,including different kinds of soft trims for both interior and exteriorapplications. Recreational vehicles, commercial truck trailers, andsimilar applications represent another category of the broadapplications of LWRT articles. Ceiling tiles, office panels, cubiclepanels and building and construction industries may also use the LWRTarticles described herein.

In some examples, the LWRT articles described herein can provide adesired level of flame retardancy and acoustic absorption or noisereduction. For example, certain articles described herein can meeteither the FMVSS 302 test or the SAE J369 test standard. These tests aregenerally equivalent and are used to determine burning ratemeasurements. In brief, the tests use a horizontal flame chamber, a fumehood, a tote large enough to handle specimens of about 12 inches inlength, a water source, a timer, a lighter and a ruler. The specimensize is about 4 inches by about 12 inches with 5 or more specimenstypically being tested. The adhesive side of the specimen is typicallysubjected to the flame. For FMVSS 302 tests, the fume hood is typicallyopened enough to provide an air flow of about 150 cubic feet per minute.For the SAE J369 test, the fume hood, for example, may be opened toprovide the same air flow or may be opened all the way. Unless otherwisenoted herein, the FMVSS 302 test can be interchanged with the SAE J369test. The results of these tests can be classified in several waysincluding DNI, SE/0, SE/NBR, SE/B, B, and RB. DNI refers to the materialnot supporting combustion during or following a 15 second ignitionperiod and/or the material not transmitting a flame front across eithersurface to a selected distance. SE/0 refers to the material igniting onthe surface, but the flame extinguishes itself before it moves aselected distance. SE/NBR refers to the material stopping burning beforeit has burned for 60 seconds from the start of timing and not burningmore than about 50 mm from the point where timing was started. SE/Brefers to the leading flame front progressing a selected distance butextinguishing itself before reaching a second distance. B refers to thematerial burning the entire distance. RB refers to the materials thatburn so rapidly it is not possible to time the burning rate. One or moreof burn distance, burn time, burn rate, and whether the material isself-extinguishing may also be measured. Specimens may be considered to“meet” or “pass” the FMVSS 302 or SAE J369 tests if the flame travelsless than about 102 mm per minute. Specimens may fail the tests if theyburn faster than 102 mm per minute.

In some configurations described herein, the presence of a flameretardant material in a thermoplastic prepreg or a thermoplastic corepermits the prepreg or core to provide flame retardancy to at least somedegree. For example, the prepreg or core (and composite articlesincluding the prepreg or core layer) may meet the Class A standard ofASTM E84 test dated 2009 and entitled “Standard Test Method for SurfaceBurning Characteristics of Building Materials”). The particular flameretardant material selected for use in the core layer may provide anarticle that meets the ASTM E84 class A or class B requirements in anas-produced article, e.g., without any molding, or in a molded articleif desired. Class A articles differ from class B articles in that classA articles have a flame spread index of about 0-25 whereas class Barticles have a flame spread index of about 26-75. In some instances,enough of the flame retardant material is present in the final prepregor core so the prepreg or core meets the class A standard under the ASTME84 test dated 2009.

In certain examples, the LWRT articles described herein may also provideacoustic absorption or noise reduction in addition to being flameretardant. Various different acoustic measurement tests can be performedto assess noise reduction including ASTM C423-17 entitled “Standard TestMethod for Sound Absorption and Sound Absorption Coefficients by theReverberation Room Method.” For example, sound absorption average (SAA)values can be measure based on the absorption at sets of frequencies.Similar to SAA, NRC (noise reduction coefficient) is also based on a setof frequencies. The sound absorption average (SAA) is defined as asingle number rating, the average, rounded to the nearest 0.01, of thesound absorption coefficient of a material for the twelve one-thirdoctave bands from 200 through 2500 Hz, inclusive. The noise reductioncoefficient (NRC) is defined from previous versions of this same testmethod as the average of the coefficients at 250, 500, 1000, and 2000Hz, expressed to the nearest integral multiple of 0.05. In NRC/SAAtests, the specimen mounting method is also specified and is describedin the ASTM E795-16 Type E 400 mounting method.

In certain configurations of the articles described herein, the articlesmay provide both flame retardancy and noise reduction. It will berecognized by the person of ordinary skill in the art, given the benefitof this disclosure, that the exact level of flame retardancy and noisereduction can depend on the materials used in the composite articles andtheir placement and orientation relative to incoming sound waves and/orpotential heat or flame sources. In some instances and referring to FIG.1, an article 100 is shown that comprises a prepreg or core layer 110coupled to an open cell skin 120. The skin 120 is disposed on a firstsurface 112 of the prepreg or core layer 110. In FIG. 1, the surface 114can be open and may not include any other layer or material disposed onit. As noted herein, the skin 120 can be disposed and coupled directlyto the prepreg or core layer 110, e.g., without using any adhesivematerial, or adhesive, spot welding or melting or other materials andtechniques can instead be used to hold the skin 120 to the prepreg orcore layer 110.

In certain examples, the prepreg or core layer 110 may comprise athermoplastic material and reinforcing fibers, which can be held inplace in the general form of a web by the thermoplastic material. Thefibers are generally arranged in a random fashion without any specificorientation or configurations. In certain examples, the thermoplasticmaterial of the prepreg or core may be present in fiber form, particleform, resin form or other suitable forms. In some instances, thethermoplastic material used in the prepreg can be present in particleform and have an average particle size that is substantially the same asthe average particle size of the flame retardant material. While notwishing to be bound by any particular scientific theory, by matching theparticles sizes of the thermoplastic material and the flame retardantmaterial, enhanced processing of the prepregs or cores including, forexample, increased loading of the flame retardant material in theprepreg or core can be achieved. In some instances, the average particlesize of the flame retardant material and the average particle size ofthe thermoplastic material can vary by about 5% to about 10% andenhanced processing can still be achieved. In certain configurations,the average particle size of each of the thermoplastic material and theflame retardant material in the prepreg can differ by about 50 micronsto about 100 microns. In some configurations, the average particle sizeof the flame retardant material is at least 50% of the average particlesize of the thermoplastic material particles to provide for enhancedprocessing. In other instances, flame retardant material with an averageparticle size about the same as the average particle size of thethermoplastic material can be present along with flame retardantmaterial of an average particle size that is different than the averageparticle size of the thermoplastic material. Even though the averageparticle size of the flame retardant material may differ, the chemicalcomposition of the flame retardant material can be the same or can bedifferent. In yet other configurations, two or more thermoplasticmaterials with different average particle sizes can be present. Ifdesired, two flame retardant materials with average particle sizes thatare substantially the same as the average particle sizes of thethermoplastic materials can be present. The two flame retardantmaterials may be chemically the same or may be chemically distinct.Similarly, the thermoplastic materials can be chemically the same (buthave a different average particle size) or can be chemically distinct.In certain instances, the virgin or native thermoplastic material usedto produce the prepreg or core may be the same thermoplastic materialthat is present in a compounded flame retardant material, e.g., amixture of flame retardant agent and a thermoplastic material. In otherinstances, the compounded flame retardant material may comprise two ormore thermoplastic materials where one of the thermoplastic materials isthe same as the virgin thermoplastic material used to produce theprepreg.

In certain embodiments, the prepreg or core 110 generally comprises asubstantial amount of open cell structure such that void space ispresent in the prepreg. For example, the prepreg or core 110 maycomprise a void content or porosity of 0-30%, 10-40%, 20-50%, 30-60%,40-70%, 50-80%, 60-90%, 0-40%, 0-50%, 0-60%, 0-70%, 0-80%, 0-90%,10-50%, 10-60%, 10-70%, 10-80%, 10-90%, 10-95%, 20-60%, 20-70%, 20-80%,20-90%, 20-95%, 30-70%, 30-80%, 30-90%, 30-95%, 40-80%, 40-90%, 40-95%,50-90%, 50-95%, 60-95% 70-80%, 70-90%, 70-95%, 80-90%, 80-95% or anyillustrative value within these exemplary ranges. In some instances, theprepreg comprises a porosity or void content of greater than 0%, e.g.,is not fully consolidated, up to about 95%. Unless otherwise stated, thereference to the prepreg or core comprising a certain void content orporosity is based on the total volume of the prepreg or core and notnecessarily the total volume of the prepreg or core plus any othermaterials or layers coupled to the prepreg or core.

In certain embodiments, the high porosity present in the prepreg permitstrapping of sound waves within the open structure of the prepreg or corelayer and can trap flame retardant material within the pores or voids.For example, flame retardant material can reside in the void space in anon-covalently bonded manner. The presence of the flame retardantmaterial in the void space can provide for enhance flame retardancy, andthe presence of void space in general can act to absorb and/or deflectsound waves within the prepreg or core 110. The flame retardant materialcan also be coated onto a surface of the prepreg to provide enhancedflame retardancy.

In certain embodiments, the thermoplastic material of the prepreg orcore 110 may comprise, at least in part, one or more of polyethylene,polypropylene, polystyrene, acrylonitrylstyrene, butadiene,polyethyleneterephthalate, polybutyleneterephthalate,polybutylenetetrachlorate, and polyvinyl chloride, both plasticized andunplasticized, and blends of these materials with each other or otherpolymeric materials. Other suitable thermoplastics include, but are notlimited to, polyarylene ethers, polycarbonates, polyestercarbonates,thermoplastic polyesters, polyimides, polyetherimides, polyamides,acrylonitrile-butylacrylate-styrene polymers, amorphous nylon,polyarylene ether ketone, polyphenylene sulfide, polyaryl sulfone,polyether sulfone, liquid crystalline polymers, poly(1,4 phenylene)compounds commercially known as PARMAX®, high heat polycarbonate such asBayer's APEC® PC, high temperature nylon, and silicones, as well asalloys and blends of these materials with each other or other polymericmaterials. The virgin thermoplastic material used to form the prepreg orcore 110 can be used in powder form, resin form, rosin form, fiber formor other suitable forms. Illustrative thermoplastic materials in variousforms are described herein and are also described, for example in U.S.Publication Nos. 20130244528 and US20120065283. The exact amount ofthermoplastic material present in the prepreg or core 110 can vary andillustrative amounts range from about 20% by weight to about 80% byweight.

In certain examples, the reinforcing fibers of the prepreg or core 110described herein can comprise glass fibers, carbon fibers, graphitefibers, synthetic organic fibers, particularly high modulus organicfibers such as, for example, para- and meta-aramid fibers, nylon fibers,polyester fibers, or any high melt flow index resins that are suitablefor use as fibers, natural fibers such as hemp, sisal, jute, flax, coir,kenaf and cellulosic fibers, mineral fibers such as basalt, mineral wool(e.g., rock or slag wool), wollastonite, alumina silica, and the like,or mixtures thereof, metal fibers, metalized natural and/or syntheticfibers, ceramic fibers, yarn fibers, or mixtures thereof. In someinstances, one type of the reinforcing fibers may be used along withmineral fibers such as, for example, fibers formed by spinning ordrawing molten minerals. Illustrative mineral fibers include, but arenot limited to, mineral wool fibers, glass wool fibers, stone woolfibers, and ceramic wool fibers. In some embodiments, any of theaforementioned fibers can be chemically treated prior to use to providedesired functional groups or to impart other physical properties to thefibers, e.g., may be chemically treated so that they can react with thethermoplastic material, the flame retardant material or both.Alternatively, the flame retardant material can be reacted with thethermoplastic material of the prepreg or core 110 to provide aderivatized thermoplastic material that is then mixed with the fibers.The total fiber content in the prepreg or core 110 may be from about 20%to about 90% by weight of the prepreg, more particularly from about 30%to about 70%, by weight of the prepreg. Typically, the fiber content ofa composite article comprising the prepreg or core 110 varies betweenabout 20% to about 90% by weight, more particularly about 30% by weightto about 80% by weight, e.g., about 40% to about 70% by weight of thecomposite. The particular size and/or orientation of the fibers used maydepend, at least in part, on the polymer material used and/or thedesired properties of the resulting prepreg. Suitable additional typesof fibers, fiber sizes and amounts will be readily selected by theperson of ordinary skill in the art, given the benefit of thisdisclosure. In one non-limiting illustration, fibers dispersed within athermoplastic material to provide a prepreg generally have a diameter ofgreater than about 5 microns, more particularly from about 5 microns toabout 22 microns, and a length of from about 5 mm to about 200 mm. Moreparticularly, the fiber diameter may be from about microns to about 22microns and the fiber length may be from about 5 mm to about 75 mm. Insome configurations, the flame retardant material may be present infiber form. For example, the prepreg or core 110 may comprise athermoplastic material, reinforcing fibers and fibers comprising a flameretardant material, e.g., fibers comprising an EG material or aninorganic flame retardant material. The flame retardant fibers maycomprise any one or more of the flame retardant materials describedherein, e.g., polypropylene fibers compounded with a hydroxide materialwhich is then extruded and cut into fibers using a suitable die or otherdevices, or EG materials mixed with polypropylene fibers compounded witha hydroxide material which is then extruded and cut into fibers using asuitable die or other devices.

In some configurations, the prepreg or core 110 may be a substantiallyhalogen free or halogen free prepreg to meet the restrictions onhazardous substances requirements for certain applications. In otherinstances, the prepreg may comprise a halogenated flame retardant agent(which can be present in the flame retardant material or may be added inaddition to the flame retardant material) such as, for example, ahalogenated flame retardant that comprises one of more of F, Cl, Br, I,and At or compounds that including such halogens, e.g., tetrabromobisphenol-A polycarbonate or monohalo-, dihalo-, trihalo- ortetrahalo-polycarbonates. In some instances, the thermoplastic materialused in the prepregs and cores may comprise one or more halogens toimpart some flame retardancy without the addition of another flameretardant agent. For example, the thermoplastic material may behalogenated in addition to there being a flame retardant materialpresent, or the virgin thermoplastic material may be halogenated andused by itself. Where halogenated flame retardants are present, theflame retardant is desirably present in a flame retardant amount, whichcan vary depending on the other components which are present. Forexample, the halogenated flame retardant where present in addition tothe flame retardant material may be present in about 0.1 weight percentto about 15 weight percent (based on the weight of the prepreg), moreparticularly about 1 weight percent to about 13 weight percent, e.g.,about 5 weight percent to about 13 weight percent. If desired, twodifferent halogenated flame retardants may be added to the prepregs. Inother instances, a non-halogenated flame retardant agent such as, forexample, a flame retardant agent comprising one or more of N, P, As, Sb,Bi, S, Se, and Te can be added. In some embodiments, the non-halogenatedflame retardant may comprise a phosphorated material so the prepregs maybe more environmentally friendly. Where non-halogenated or substantiallyhalogen free flame retardants are present, the flame retardant isdesirably present in a flame retardant amount, which can vary dependingon the other components which are present. For example, thesubstantially halogen free flame retardant may be present in about 0.1weight percent to about 15 weight percent (based on the weight of theprepreg), more particularly about 1 weight percent to about 13 weightpercent, e.g., about 5 weight percent to about 13 weight percent basedon the weight of the prepreg. If desired, two different substantiallyhalogen free flame retardants may be added to the prepregs. In certaininstances, the prepregs described herein may comprise one or morehalogenated flame retardants in combination with one or moresubstantially halogen free flame retardants. Where two different flameretardants are present, the combination of the two flame retardants maybe present in a flame retardant amount, which can vary depending on theother components which are present. For example, the total weight offlame retardants present may be about 0.1 weight percent to about 20weight percent (based on the weight of the prepreg or core), moreparticularly about 1 weight percent to about 15 weight percent, e.g.,about 2 weight percent to about 14 weight percent based on the weight ofthe prepreg or core. The flame retardant agents used in the prepregs orcores described herein can be added to the mixture comprising thethermoplastic material and fibers (prior to disposal of the mixture on awire screen or other processing component) or can be added after theprepreg or core is formed.

In other configurations described herein and as noted above, thecomposite article may comprise a flame retardant material such that thecomposite article meets ASTM E84 or the SAE J369 method (REV. November2007). This test method is referred to in certain instances in thedescription and claims as a SAE flammability test or a SAEself-extinguishing test. In some examples, less than 10 weight percentflame retardant materials, less than 9 weight percent flame retardantmaterials, less than 8 weight percent flame retardant materials, lessthan 7 weight percent flame retardant materials, less than 6 weightpercent flame retardant materials or even less than 5 weight percentflame retardant materials can be present in the prepreg or core layer sothe composite article meets or passes the non-oil soaked and oil-soakedSAE flammability tests.

In certain embodiments, the flame retardant agent may comprise manydifferent materials including organic and inorganic flame retardantmaterials. In certain examples, expandable graphite materials can beused in the prepreg or core 110 and may comprise one or more graphenebased materials typically present in stacked molecular layers. While notwishing to be bound by any particular theory, in addition to providinglofting capabilities, the expandable graphite materials also can providesome degree of flame retardancy. In some embodiments, enough expandablegraphite materials is present, e.g., a flame retardant amount ofexpandable graphite materials is present, in the prepreg or core 110such that the prepreg or core 110 meets the ASTM E84 test dated 2009 ormeets the Federal Motor Vehicle Safety Standard 302 (FMVSS 302)flammability test dated 1991, which is generally equivalent to ISO 3795dated 1989 and ASTM D5132 dated 2004. Such flame retardant amounts canpermit construction of a prepreg or core 110 that is substantially freeof external flame retardant agents. The exact type of expandablegraphite materials used in the prepreg can depend on numerous factorsincluding, for example, the desired lofting temperature, the desiredflame retardancy, desired acoustic performance, etc. Illustrativecommercially available expandable graphite materials are available fromNyacol Nano Technologies, Inc. (Ashland, Mass.) and include, forexample, grades 35, 200, 249, 250, 251, KP251 and 351 expandablegraphite materials. Additional expandable graphite material can bepurchased commercially from Graftech International (Lakewood, Ohio).While not wishing to be bound by any particular reaction, expandablegraphite material can generally be produced by acidifying a graphiteore. Acidification results in an intercalation process, e.g., wheresulfuric acid acts as an intercalator. The solution can then beneutralized to provide a series of layers of sheets of hexagonalcarbon-carbon bonded materials. The layers are generally flat andinteract with additional hexagonal carbon-carbon layers to provide alayered sheet structure. The layered sheet structure can be heldtogether through covalent bonding or electrostatic interactions (orboth) between sheets. Heating of the expandable graphite material in thethermoplastic prepreg or core 110 described herein can result inincreased separation between layers and a resulting increase inthickness of the prepreg. If desired, the expandable graphite materialcan be oxidized using a suitable oxidant to form a graphene oxide. Asnoted herein, the expandable graphite material can be present in manyforms including flake form, particle form or other forms. In someinstances, the expandable graphite material is present in particle formand may comprise an average particle size of at least 300 microns, forexample.

In certain configurations, the flame retardant agent may comprise aninorganic material or inorganic salt. For example, restrictions onhazardous substances (RoHS) may make it desirable to select the flameretardant material as an inorganic salt that is substantially free (orfree) of any halides. In some embodiments, the flame retardant materialmay comprise a group II metal or a group III metal in combination withone or more anions. For example, the flame retardant material maycomprise beryllium, calcium, magnesium or other Group II metal salts. Insome embodiments, the Group II metal of the flame retardant material maybe present as a hydroxide material. For example, the flame retardantmaterial may be present as beryllium hydroxide, calcium hydroxide,magnesium hydroxide (MDH) or other group II metal hydroxides. In otherinstances, the flame retardant material may comprise aluminum, gallium,indium or other Group III metal salts. In some embodiments, the GroupIII metal salt of the flame retardant material may be present as ahydroxide material. For example, the flame retardant material may bepresent as aluminum hydroxide (ATH) or gallium hydroxide or other groupIII metal hydroxides. In other configurations, the inorganic materialpresent as a flame retardant material may comprise one or moretransition metal salts which can function as flame retardant materials.For example, transition metals which can form divalent cations insolution may be combined with one or more anions and used as flameretardant agents. In some instances, the transition metal salt may bepresent in non-halide form, e.g., may not be present as a fluoride,chloride, bromide or iodide salt, to avoid outgassing of toxic gasesshould the prepreg or core undergo burning. In certain configurations,the transition metal salt may be present, for example, as a hydroxide.

The exact amount of the flame retardant material used in the prepregsand cores may vary depending on which other materials are present, butthe flame retardant material typically is present at a weight percentageless than a major amount of the prepreg or core, e.g., the flameretardant material is typically present at 50 weight percent or lessbased on the weight of the prepreg or core. In certain instances, theflame retardant material is present above a minor amount to provideflame retardancy to the prepreg or core. For example, the flameretardant material may be present at 30 weight percent or more, 35weight percent or more, 40 weight percent or more or even 45 weightpercent or more based on the weight of the prepreg or core. For example,the flame retardant material:other material ratio may vary from 1:1, 2:13:1, 4:1:5:1, 1:5, 1:4, 1:3 or 1:2.

Depending on the particular process used to produce the prepregs orcore, the flame retardant material can be ground, filtered, sized orotherwise processed prior to adding it to the other materials of theprepreg or core. In some instances where thermoplastic particles areused in the prepreg or core, the average particle size of the flameretardant material may be about the same as the average particle size ofthe thermoplastic material. In other configurations, the averageparticle size of the flame retardant material may be smaller or largerthan the average particle size of the thermoplastic material used in theprepreg or core.

In certain configurations, a porous prepreg or core comprising one ormore thermoplastic materials and a plurality of fibers that togetherprovide an open cell structure, e.g., void space, can be produced. Insome configurations, flame retardant materials, e.g., EG materials,Group II metal salts, Group III metal salts, etc. can be loaded into thevoid space in a manner where the flame retardant materials reside (atleast in part) within the void space formed by crossing over of thefibers, which can be held in place by the thermoplastic material. Insome instances, the thermoplastic materials and/or the fibers can beselected so that they are generally inert or non-reactive with the flameretardant materials. In some examples, the flame retardant materials maynot covalently bond to the thermoplastic material and/or the fibers, butthere may be an association between any charged flame retardant materialwith the thermoplastic material of the porous prepreg. For example, weakinteractions such as van der Waals' interactions or electrostaticinteractions can take place between the flame retardant material and theother components of the prepreg or core.

In certain embodiments, the open cell skin 120 generally comprises asufficient amount of open surface area to permit entry of sound wavesinto the prepreg or core 110. The open structure may exist within thefilm itself, e.g., by way of a network of cross-linked materials in thefilm, or may be provided by processing a film using suitable methodsincluding creating perforations, slits, apertures, opening, punches orother structures which will increase the open surface area of the film.In some examples, the open cell skin comprises an open surface area ofat least 5,%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15% or more(based on the overall surface area of the skin). In some instances, theopen surface area of the skin is selected to provide a desired noisereduction coefficient but is not so open that it lacks proper structureto function as a film.

In some instances, the materials used in the open cell skin may be apolyolefin, a co-polymer comprising a polyolefin, a polyamide, aco-polymer comprising a polyamide, or combinations thereof. The exactbasis weight of the open cell skin or open cell film may vary from about10 gsm to about 150 gsm, e.g., about 70-120 gsm or about 80-110 gsm orabout 85-100 gsm, though the open cell skin or open cell film may belighter or heavier depending on the exact open surface area present. Insome instances, the open cell skin may take the form of an open cellfilm, an open cell scrim, an open cell frim (film+scrim) or other opencell layers. For example, the open cell skin may comprise an open cellpolyethylene film, an open cell polypropylene film or an open cellpolyamide film or combinations thereof.

In certain embodiments and as noted herein, the open cell skin and theprepreg or core can together provide both flame retardancy and noisereduction. For example, when used together, the open cell skin andprepreg or core layer may provide an article with a noise reductioncoefficient of at least 0.5 as tested by ASTM C423-17, a flame spreadindex of less than 25 and a smoke development index of less than 150 astested by ASTM E84 dated 2009. In other configurations, the open cellskin and prepreg or core layer may together provide an article with anoise reduction coefficient of at least 0.65 as tested by ASTM C423-17,a flame spread index of less than 25 and a smoke development index ofless than 150 as tested by ASTM E84 dated 2009. In some examples, theopen cell skin and prepreg or core layer may together provide an articlewith a noise reduction coefficient of at least 0.75 as tested by ASTMC423-17, a flame spread index of less than 25 and a smoke developmentindex of less than 150 as tested by ASTM E84 dated 2009. In additionalexamples, the open cell skin and prepreg or core layer may togetherprovide an article with a noise reduction coefficient of at least 0.85as tested by ASTM C423-17, a flame spread index of less than 25 and asmoke development index of less than 150 as tested by ASTM E84 dated2009. In other examples, the open cell skin and prepreg or core layermay together provide an article with a noise reduction coefficient of atleast 0.85 as tested by ASTM C423-17, a flame spread index of less than25 and a smoke development index of less than 150 as tested by ASTM E84dated 2009. In some examples, the open cell skin and prepreg or corelayer may together provide an article with a noise reduction coefficientof at least 0.88 or 0.9 as tested by ASTM C423-17, a flame spread indexof less than 25 and a smoke development index of less than 150 as testedby ASTM E84 dated 2009.

In certain embodiments, the open cell skin need not have the sameporosity or structure across an entire planar surface of the film.Referring to FIG. 2, an article 200 comprises a prepreg or core layer210 and an open cell skin 220 disposed on a surface of the layer 210.The open cell skin 220 comprises an area 222 with a first open surfacearea and areas 224, 226 with a different surface area than the area 222.The open surface area of the areas 224, 226 need not be the same thoughthey may be the same. In some instances, the open surface area at areas224, 226 is greater than the open surface area at area 222, whereas inother instances the open surface area at areas 224, 226 is less than theopen surface area at area 222. For example, where the composite articleis used as a cubicle panel, ceiling tile or wall structure, the areas atthe edges of the article may not need to provide the same noisereduction coefficient as the central portion of the article. In otherinstances, it may be desirable to vary the open surface area across aplanar surface of the skin 220 to provide different noise reductioncoefficients at different frequencies. For example, where the article isconfigured for use in movie theater ceiling tiles, it may be desirableto configure the skin 220 to comprise different noise coefficientreductions at different areas so the skin 220 provides variable noisereduction. The prepreg or core layer 210 may comprise any of thosecomponents described in reference to the prepreg or core layer 110 andgenerally is configured as a “heavy” layer with an areal weight of atleast 2000 gsm or at least 2100 gsm or at least 2200 gsm or at least2300 gsm or at least 2400 gsm or at least 2500 gsm. For example, theprepreg or core layer 210 may comprise one or more thermoplasticmaterials, a flame retardant material and reinforcing fibers randomlyarranged in the prepreg or core layer 210.

In other examples, two or more different open cell skins can be layeredon a core layer. Referring to FIG. 3, a composite article 300 comprisesa prepreg or core layer 300, a first open cell skin 320 disposed on theprepreg or core layer 320 and a second open cell skin 330 disposed onthe first open cell skin 320. In some instances, the first skin 320 maycomprise a higher open surface area than an open surface area of thesecond skin 330, whereas in other instances, the first skin 320 maycomprise a lower open surface area than the open surface area of thesecond skin 330. If desired, the skins 320, 330 can be melted or coupledto each other to provide a single composite skin layer prior todisposing the skins 320, 330 on the prepreg or core layer 310. Inaddition, more than two skin layers can be coupled to each other ifdesired. In some examples, the outermost skin may have the highest opensurface area to permit sound waves to enter in the layered skinstructure with the skin closer to the prepreg or core layer 320 having alower open surface area than the outer film layers. This illustrativeskin arrangement can permit capture or more sound waves within thelayered skin structure and the prepreg or core layer 310 than when onlya single skin layer is used. The prepreg or core layer 310 may compriseany of those components described in reference to the prepreg or corelayer 110 and generally is configured as a “heavy” prepreg or core layerwith an areal weight of at least 2000 gsm or at least 2100 gsm or atleast 2200 gsm or at least 2300 gsm or at least 2400 gsm or at least2500 gsm. For example, the prepreg or core layer 310 may comprise one ormore thermoplastic materials, a flame retardant material and reinforcingfibers randomly arranged in the prepreg or core layer 310.

In some configurations, one or more non-film layers can be coupled tothe open cell skin. Referring to FIG. 4, an article 400 comprises aprepreg or core layer 410 with an open cell skin 420 disposed on theprepreg or core layer 410. A surface layer 440 or skin is disposed onthe open cell skin 420. As noted in more detail below, the surface layer440 can take many different configurations and is desirably porous oropen to permit sound waves to enter into the composite article 400through the surface layer 440 and into the skin 420 and core layer 410.

The layer 440 may comprise, for example, a scrim (e.g., fiber basedscrim), a foil, a woven fabric, a non-woven fabric or be present as aninorganic coating, an organic coating, or a thermoset coating disposedon the prepreg or core 410. In other instances, the layer 440 maycomprise a limiting oxygen index greater than about 22, as measured perISO 4589 dated 1996. Where a fiber based scrim is present as (or as partof) the layer 440, the fiber based scrim may comprise at least one ofglass fibers, aramid fibers, graphite fibers, carbon fibers, inorganicmineral fibers, metal fibers, metalized synthetic fibers, and metalizedinorganic fibers. Where a thermoset coating is present as (or as partof) the layer 440, the coating may comprise at least one of unsaturatedpolyurethanes, vinyl esters, phenolics and epoxies. Where an inorganiccoating is present as (or as part of) the layer 440, the inorganiccoating may comprise minerals containing cations selected from Ca, Mg,Ba, Si, Zn, Ti and Al or may comprise at least one of gypsum, calciumcarbonate and mortar. Where a non-woven fabric is present as (or as partof) the layer 440, the non-woven fabric may comprise a thermoplasticmaterial, a thermal setting binder, inorganic fibers, metal fibers,metallized inorganic fibers and metallized synthetic fibers.

If desired, a second surface layer or skin can be present on an oppositesurface of the core layer 410. For example and referring to FIG. 4B, asecond surface layer 460 is disposed on an opposite surface of theprepreg or core layer 410 to provide a composite article 450. The secondsurface layer 460 can be the same or different than the surface layer440 and may be any one or more of those materials described in referenceto the surface layer 440. The prepreg or core layer 410 may comprise anyof those components described in reference to the prepreg or core layer110 and generally is configured as a “heavy” prepreg or core layer withan areal weight of at least 2000 gsm or at least 2100 gsm or at least2200 gsm or at least 2300 gsm or at least 2400 gsm or at least 2500 gsm.For example, the prepreg or core layer 410 may comprise one or morethermoplastic materials, a flame retardant material and reinforcingfibers randomly arranged in the prepreg or core layer 410.

In certain configurations, the composite articles described herein maycomprise one or more closed cell skins. Referring to FIG. 5, a compositearticle 500 comprises a prepreg or core layer 510 coupled to an opencell skin 520 on a first surface 512 and coupled to a closed cell skin530 at a second surface 514. Without wishing to be bound by anyparticular theory, sound waves can enter into the article 500 throughthe open cell skin 520 and into the core layer 510. The closed cell skin530 can act to reflect sound waves back into the core layer 510 and theskin 520 to absorb the sound waves. Sound waves incident on the closedcell skin 530 may generally be reflected so that those sound waves donot pass through the article 500. By configuring the article 500 withboth an open cell skin 520 and a closed cell skin 530, sound waves canabsorbed through one surface and reflected by another surface to providefor increased noise reduction coefficients using the article 500. Theopen cell skin 520 may be any of those films described above inconnection with the film layer 120.

The closed cell skin 530 generally comprises a lower open surface areathan the open cell skin 520 and may comprise a heavier areal weight (fora comparable thickness) compared to an areal weight of the open cellskin 520. In some examples, even though the skin 530 is a closed cellskin, the skin 530 may permit transmission of water vapor through thearticle 500 to reduce the likelihood of mold growth and/or to permittransfer of water from one side of the article 500 to the other side ofthe article 500. The exact open surface area of the closed cell skin 530may vary, for example, from about 0% to less than 10%, e.g., 1-9% or2-8% or 3-7% or 4-6% or less than 5% open area. When an open cell skinand a closed cell skin are used together, the open surface area of theclosed cell skin may be at least 50% less than an open surface area ofthe open cell skin or at least 75%, 80%, 85% or 90% less than an opensurface area of the open cell skin. In some examples, the closed cellskin may be configured as a closed cell film, a closed cell scrim, aclosed cell frim or other closed cell layers and materials.

While the exact materials and configurations used for the closed cellskin 530 may vary, illustrative materials include but are not limited topolyethylene skins such as a closed cell polyethylene film,polypropylene skins such as a closed cell polypropylene film orpolyamide skins such as a closed cell polyamide film or combinationsthereof. In some examples, the closed cell skin 530 may be similar tothe open cell skin 520, e.g., may comprise the same materials such aspolyolefin materials and polyamide materials, but the open cell skin 520may comprise perforations or holes to increase the overall porosity orpermeability of the skin 520 to permit sound waves to enter into theunderlying core layer 500 through the skin 520. For example, the samefilm material can be used on both surfaces of a core layer, but the filmon one surface of the core layer may be processed to provideperforations or openings prior to (or after) disposing the film on asurface of the core layer. The prepreg or core layer 510 may compriseany of those components described in reference to the prepreg or corelayer 110 and generally is configured as a “heavy” prepreg or core layerwith an areal weight of at least 2000 gsm or at least 2100 gsm or atleast 2200 gsm or at least 2300 gsm or at least 2400 gsm or at least2500 gsm. For example, the prepreg or core layer 510 may comprise one ormore thermoplastic materials, a flame retardant material and reinforcingfibers randomly arranged in the prepreg or core layer 510.

In certain examples, the composite articles described herein maycomprise one or more surface layers on an opposite surface of a corelayer than where an open cell film is present. Referring to FIG. 6, acomposite article 600 comprises a prepreg or core layer 610 coupled toan open cell skin 620 on a first surface 612 and coupled to a surfacelayer 650 at a second surface 614. The surface layer 650 may be any ofthose surface layers or skins described in reference to surface layer440 above. If desired, the surface layer may also comprise a closed cellskin disposed on one or more surfaces. The open cell skin 620 may be anyof those skins described above in connection with the skin layer 120,e.g., an open cell film, an open cell scrim, an open cell frim, etc. Theprepreg or core layer 610 may comprise any of those components describedin reference to the prepreg or core layer 110 and generally isconfigured as a “heavy” prepreg or core layer with an areal weight of atleast 2000 gsm or at least 2100 gsm or at least 2200 gsm or at least2300 gsm or at least 2400 gsm or at least 2500 gsm. For example, theprepreg or core layer 610 may comprise one or more thermoplasticmaterials, a flame retardant material and reinforcing fibers randomlyarranged in the prepreg or core layer 610.

In certain embodiments and referring to FIG. 7, an article 700 maycomprise a prepreg or core layer 710, an open cell skin 720 disposed ona first surface 712 of the layer 710, a closed cell skin 730 disposed onanother surface 714 of layer 710 and a surface layer 750 disposed on theopen cell skin 720. The open cell skin 720 may be any of those filmsdescribed above in connection with the open cell skin 120, e.g., an opencell film, an open cell scrim, an open cell frim, etc. The closed cellskin 730 may be any of those closed cell films described above inconnection with the closed cell film 530, e.g., a closed cell film, aclosed cell scrim, a closed cell frim, etc. The prepreg or core layer710 may comprise any of those components described in reference to theprepreg or core layer 110 and generally is configured as a “heavy”prepreg or core layer with an areal weight of at least 2500 gsm. Forexample, the prepreg or core layer 710 may comprise one or morethermoplastic materials, a flame retardant material and reinforcingfibers randomly arranged in the prepreg or core layer 710.

In certain configurations, an open cell skin may be coupled to more thana single prepreg or core layer. For example and referring to FIG. 8, acomposite article 800 comprises a first core layer 810 and a second corelayer 815 separated by an open cell skin 820. The prepreg or core layers810, 815 may be the same or may be different. In some instances, thelayers 810, 815 generally comprise the same materials but may comprisedifferent areal weights. For example, the weight of the prepreg or corelayer 810 may be greater than or less than the weight of the prepreg orcore layer 815. The layers 810, 815 may independently comprise any ofthose components described in reference to the prepreg or core layer110. For example, one or both of the layers 810, 815 can be configuredas a “heavy” prepreg or core layer with an areal weight of at least 2000gsm or at least 2100 gsm or at least 2200 gsm or at least 2300 gsm or atleast 2400 gsm or at least 2500 gsm. In some instances, each of theprepreg or core layers 810, 615 may comprise one or more thermoplasticmaterials, a flame retardant material and reinforcing fibers randomlyarranged in the prepreg or core layers 810, 815. The thermoplasticmaterials, reinforcing fibers and flame retardant agent need not be thesame in the different prepreg or core layers 810, 815. If desired, thesum of the weights of the two layers 810, 815 may be at least 2500 gsmwith each layer contributing some weigh to the total weight, but thelayers 810, 815 need not weigh the same. The open cell skin 820 may beany of those open cell skins described in connection with the open cellskin 120, e.g., an open cell film, an open cell scrim, an open cellfrim, etc. While not shown, one or more surface layers can be coupled tothe core layer 810, the core layer 815 or both if desired.

In certain examples, an open cell skin may be coupled to more than asingle prepreg or core layer that is coupled to another open cell film.For example and referring to FIG. 9, a composite article 900 comprises afirst core layer 910 and a second core layer 915 separated by an opencell skin 920. The core layer 915 comprises a second open cell skin 925disposed on a surface. In some instances, the layers 910, 915 generallycomprise the same materials but may comprise different areal weights.For example, the weight of the prepreg or core layer 910 may be greaterthan or less than the weight of the prepreg or core layer 915. Thelayers 910, 915 may independently comprise any of those componentsdescribed in reference to the prepreg or core layer 110. For example,one or both of the layers 910, 915 can be configured as a “heavy”prepreg or core layer with an areal weight of at least 2000 gsm or atleast 2100 gsm or at least 2200 gsm or at least 2300 gsm or at least2400 gsm or at least 2500 gsm. In some examples, the prepreg or corelayers 910, 915 may comprise one or more thermoplastic materials, aflame retardant material and reinforcing fibers randomly arranged ineach of the prepreg or core layers 910, 915. The thermoplasticmaterials, reinforcing fibers and flame retardant agent need not be thesame in each of the layer 910, 915. If desired, the sum of the weightsof the two layers 910, 915 may be at least 2500 gsm with each layercontributing some weigh to the total weight, but the layers 910, 915need not weigh the same. Each of the open cell skins 920, 925 mayindependently be any of those open cell skins described in connectionwith the open cell skin 120, e.g., an open cell film, an open cellscrim, an open cell frim, etc. Each of the open cell skins 920, 925 mayalso be the same or may be different. In some examples, the open surfacearea of the skin 925 may be greater than an open surface area of theskin 920 to permit sound waves to penetrate into the article 900.Further, the thickness of the skins 920, 925 can be the same or can bedifferent. In some instances, the skins 920, 925 may be produced fromthe same skin, but the skin 925 may have an increased number ofperforations or holes compared to a number of perforations or holespresent in the skin 920. While not shown, one or more surface layers canbe coupled to the skin 925, the core layer 910 or both if desired.

In some configurations, an open cell skin may be coupled to more than asingle prepreg or core layer that is coupled to another open cell filmand a closed cell film. For example and referring to FIG. 10, acomposite article 1000 comprises a first core layer 1010 and a secondcore layer 1015 separated by an open cell skin 1020. A closed cell skin1030 is coupled to an opposite surface of the core layer 1010. In someinstances, the layers 1010, 1015 generally comprise the same materialsbut may comprise different areal weights. For example, the weight of theprepreg or core layer 1010 may be greater than or less than the weightof the prepreg or core layer 1015. The layers 1010, 1015 mayindependently comprise any of those components described in reference tothe prepreg or core layer 110. For example, one or both of the layers1010, 1015 can be configured as a “heavy” prepreg or core layer with anareal weight of at least 2000 gsm or at least 2100 gsm or at least 2200gsm or at least 2300 gsm or at least 2400 gsm or at least 2500 gsm. Insome instances, the prepreg or core layer 1010 may comprise one or morethermoplastic materials, a flame retardant material and reinforcingfibers randomly arranged in the prepreg or core layer 1010. Thethermoplastic materials, reinforcing fibers and flame retardant agent inthe layers 1010, 1015 need not be the same. If desired, the sum of theweights of the two layers 1010, 1015 may be at least 2500 gsm with eachlayer contributing some weigh to the total weight, but the layers 1010,1015 need not weigh the same. The open cell skin 1020 may be any ofthose open cell skins described in connection with the open cell skin120, e.g., an open cell film, an open cell scrim, an open cell frim,etc. The closed cell skin 1030 may be any of those closed cell skinsdescribed in connection with the closed cell film 530, e.g., a closedcell film, a closed cell scrim, a closed cell frim, etc. While notshown, one or more surface layers can be coupled to the core layer 1015,the closed cell skin 1030 or both if desired.

Additional layers such as decorative layers, textured layers, coloredlayers and the like may also be present in the composite articlesdescribed herein. For example, a decorative layer may be formed, e.g.,from a thermoplastic film of polyvinyl chloride, polyolefins,thermoplastic polyesters, thermoplastic elastomers, or the like. Thedecorative layer may also be a multi-layered structure that includes afoam core formed from, e.g., polypropylene, polyethylene, polyvinylchloride, polyurethane, and the like. A fabric may be bonded to the foamcore, such as woven fabrics made from natural and synthetic fibers,organic fiber non-woven fabric after needle punching or the like, raisedfabric, knitted goods, flocked fabric, or other such materials. Thefabric may also be bonded to the foam core with a thermoplasticadhesive, including pressure sensitive adhesives and hot melt adhesives,such as polyamides, modified polyolefins, urethanes and polyolefins. Thedecorative layer may also be produced using spunbond, thermal bonded,spun lace, melt-blown, wet-laid, and/or dry-laid processes. Insulationlayers may also be bonded to one or more surfaces of the articlesdescribed herein, and the insulation layers may be open or closed, e.g.,an open cell foam or a closed cell foam, as desired.

In certain embodiments, any one or more of the articles describedherein, e.g., those described in reference to FIGS. 1-10, can beconfigured as a ceiling tile to absorb sound and to provide flameretardancy. Referring to FIG. 11, a grid of ceiling tiles 1100 is shownthat comprises support structures 1102, 1103, 1104 and 1105 with aplurality of ceiling tiles, such as tile 1110, laid into the grid formedby the support structures. As noted herein, the open cell skin of theceiling tile is typically oriented toward a noise source to permit noiseabsorption. In some cases, the open cell skin of the ceiling tile facestoward an interior of a room, e.g., when noises from the room aredesired to be reduced, whereas in other instances the open cell skin ofthe ceiling tile faces away from an interior of a room, e.g., whennoises from ceiling mounted and suspended HVAC devices are desired to bereduced.

In some examples, the ceiling tile comprises a porous core layercomprising a web of open celled structures comprising a randomarrangement of a plurality of reinforcing fibers held together by athermoplastic material, wherein the porous core layer comprises a flameretardant agent and an areal or basis weight of at least 2000 gsm or atleast 2100 gsm or at least 2200 gsm or at least 2300 gsm or at least2400 gsm or at least 2500 gsm, and an open cell skin disposed on a firstsurface of the porous core layer, wherein the ceiling tile comprises anoise reduction coefficient of at least 0.5 as tested by ASTM C423-17,and wherein the ceiling tile comprises a flame spread index of less than25 and a smoke development index of less than 150 as tested by ASTM E84dated 2009. For example, the open cell skin comprises an open surfacearea of at least 10%. If desired, the ceiling tile comprises a noisereduction coefficient of at least 0.85 as tested by ASTM C423-17. Insome examples, the ceiling tile may comprise a porous decorative layerdisposed on the open cell skin, e.g., a fabric, cloth, or other layers.In certain instances, the flame retardant agent in the ceiling tilecomprises expandable graphite particles or magnesium hydroxide or both.In some examples, the open cell skin comprises a perforated film with anopen surface area of at least 10%, and wherein the ceiling tile panelcomprises a noise reduction coefficient of at least 0.85 as tested byASTM C423-17. In certain instances, the ceiling tile may also comprise aclosed cell skin disposed on a second surface of the porous core layer.In further examples, the flame retardant agent can be homogeneouslydispersed in the porous core layer. In some examples, the thermoplasticmaterial comprises a polyolefin resin. In certain embodiments, theplurality of reinforcing fibers comprise glass fibers or mineral fibersor both. In some instances, the porous core layer of the ceiling tilefurther comprises a clay.

In certain embodiments, any one or more of the articles describedherein, e.g., those described in reference to FIGS. 1-10, can beconfigured as a cubicle panel to absorb sound and to provide flameretardancy. Referring to FIG. 12, a top view of a cubicle 1200comprising side panels 1210, 1230 and center panel 1230 are shown. Anyone or more of the panels 1210-1230 may comprise one of the LWRTarticles described herein. As noted herein, the open cell skin of thecubicle panel is typically oriented toward a noise source to permitnoise absorption. In some cases, the open cell skin of the cubicle panelfaces toward an interior of the cubicle space, e.g., when noises fromwithin the cubicle are desired to be reduced, whereas in other instancesthe open cell skin of the cubicle panel faces away from an interior ofthe cubicle space, e.g., when noises from outside the cubicle are to bereduced. If desired, two or more cubicle panels can be sandwiched withone open cell skin facing into the interior of the cubicle space and theopen cell skin of the other cubicle panel facing outward away from theinterior cubicle space.

In some examples, the cubicle wall panel is sized and arranged to coupleto another cubicle wall panel and comprises a porous core layercomprising a web of open celled structures comprising a randomarrangement of a plurality of reinforcing fibers held together by athermoplastic material, wherein the porous core layer comprises a flameretardant agent and an areal or basis weight of at least 2000 gsm or atleast 2100 gsm or at least 2200 gsm or at least 2300 gsm or at least2400 gsm or at least 2500 gsm, and an open cell skin disposed on a firstsurface of the porous core layer, wherein the cubicle wall panelcomprises a noise reduction coefficient of at least 0.5 as tested byASTM C423-17, and wherein the cubicle wall panel comprises a flamespread index of less than 25 and a smoke development index of less than150 as tested by ASTM E84 dated 2009. In some instances, the open cellskin comprises an open surface area of at least 10%. The cubicle wallpanel may comprise a noise reduction coefficient of at least 0.85 astested by ASTM C423-17. In other instances, the cubicle wall panelcomprises a porous decorative layer disposed on the open cell skin. Infurther examples, the flame retardant agent in the cubicle wall panelcomprises expandable graphite particles or magnesium hydroxide or both.In some configurations, the open cell skin comprises a perforated filmwith an open surface area of at least 10%, and wherein the cubicle wallpanel comprises a noise reduction coefficient of at least 0.85 as testedby ASTM C423-17. In other instances, the cubicle wall panel comprises aclosed cell skin disposed on a second surface of the porous core layer.In some examples, the flame retardant agent is homogeneously dispersedin the porous core layer. In other examples, the thermoplastic materialcomprises a polyolefin resin. In certain embodiments, the plurality ofreinforcing fibers comprise glass fibers or mineral fibers or both. Insome instances, In some examples, the porous core layer of the cubiclewall panel further comprises a clay.

In certain embodiments, any one or more of the articles describedherein, e.g., those described in reference to FIGS. 1-10, can beconfigured as a structural panel to absorb sound and to provide flameretardancy. The structural panel can be used, for example, assub-flooring, wall sheathing, roof sheathing, as structural support forcabinets, countertops and the like, as stair treads, as a replacementfor plywood and other applications. If desired, the structural panel canbe coupled to another substrate such as, for example, plywood, orientedstrand board or other building panels commonly used in residential andcommercial settings. Referring to FIG. 13A, a top view of a structuralpanel 1310 is shown. The panel 1310 may comprise any one of the LWRTarticles described herein. As noted herein, the open cell skin of thestructural panel is typically oriented toward a noise source to permitnoise absorption. In some cases, the open cell skin of the structuralpanel faces toward an interior of a room, e.g., when noises from withinthe room are to be reduced, whereas in other instances the open cellskin of the structural panel faces away from an interior of a room,e.g., when noises from outside the room are to be reduced. If desired,two or more structural panels can be sandwiched with one open cell skinfacing into the interior of the room and the open cell skin of the otherstructural panel facing outward away from the interior of the room.

In some instances, the structural panel may also comprise a structuralsubstrate 1320. For example, a structural panel may comprise a porouscore layer comprising a web of open celled structures comprising arandom arrangement of a plurality of reinforcing fibers held together bya thermoplastic material, wherein the porous core layer comprises aflame retardant agent and an areal or basis weight of at least 2000 gsmor at least 2100 gsm or at least 2200 gsm or at least 2300 gsm or atleast 2400 gsm or at least 2500 gsm, an open cell skin coupled to afirst surface of the porous core layer, and a structural substrate 1320coupled to a second surface of the porous core layer, wherein thestructural panel comprises a flame spread index of less than 25 and asmoke development index of less than 150 as tested by ASTM E84 dated2009, and wherein the structural panel provides a noise reductioncoefficient of at least 0.85 as tested by ASTM C423-17. The exact natureof the structural substrate 1320 may vary and includes, but is notlimited to, plywood, gypsum board, wood planks, wood tiles, cementboard, oriented strand board, polymeric or vinyl or plastic panels andthe like. In some examples, the structural substrate comprises a plywoodpanel, a gypsum board, a wood tile, a ceramic tile, a metal tile, a woodpanel, a concrete panel, a concrete board or a brick. In other examples,the open cell skin comprises an open surface area of at least 10%. Ifdesired, the structural panel may comprise a noise reduction coefficientof at least 0.85 as tested by ASTM C423-17. In some instances, thestructural panel may comprise a porous decorative layer disposed on theopen cell skin. In other examples, the flame retardant agent comprisesexpandable graphite particles or magnesium hydroxide or both. In someexamples, the open cell skin comprises a perforated film with an opensurface area of at least 10%, and wherein the structural panel comprisesa noise reduction coefficient of at least 0.85 as tested by ASTMC423-17. In some examples, the structural panel comprises a closed cellskin disposed on a second surface of the porous core layer. In otherexamples, the flame retardant agent is homogeneously dispersed in theporous core layer. In some embodiments, the thermoplastic materialcomprises a polyolefin resin and the plurality of reinforcing fiberscomprise glass fibers or mineral fibers or both. If desired, thestructural panel may further comprise a second structural panel coupledto the open cell skin, wherein the second structural panel is a porousstructural panel.

In certain instances, any one or more of the articles described herein,e.g., those described in reference to FIGS. 1-10, can be configured as awall board or wall panel to absorb sound and to provide flameretardancy. The wall panel can be used, for example, to cover studs orstructural members in a building, to cover ceiling joists or trusses andthe like. If desired, the wall panel can be coupled to another substratesuch as, for example, tile, wood paneling, gypsum, concrete backerboard, or other wall panel substrates commonly used in residential andcommercial settings. Referring to FIG. 14, a side view of a wall panel1400 is shown. The panel 1400 may comprise any one of the LWRT articlesdescribed herein. As noted herein, the open cell skin of the wall panelis typically oriented toward a noise source to permit noise absorption.In some cases, the open cell skin of the wall panel faces toward aninterior of a room, e.g., when noises from within the room are to bereduced, whereas in other instances the open cell skin of the wall panelfaces away from an interior of a room, e.g., when noises from outsidethe room are to be reduced. If desired, two or more wall panels can besandwiched with one open cell skin facing into the interior of the roomand the open cell skin of the other wall panel facing outward away fromthe interior of the room.

In some instances, the wall panel 1400 comprises a porous core layer1410 comprising a web of open celled structures comprising a randomarrangement of a plurality of reinforcing fibers held together by athermoplastic material, wherein the porous core layer comprises a flameretardant agent and an areal or basis weight of at least 2000 gsm or atleast 2100 gsm or at least 2200 gsm or at least 2300 gsm or at least2400 gsm or at least 2500 gsm. The wall panel 1400 may also comprise anopen cell skin 1420 coupled to a first surface of the porous core layer1410. As noted herein, an optional wall substrate can be coupled to asecond surface of the porous core layer 1410 and configured to supportthe porous core layer 1410 when the wall panel 1400 is coupled to a wallsurface, wherein the wall panel comprises a flame spread index of lessthan 25 and a smoke development index of less than 150 as tested by ASTME84 dated 2009, and wherein the wall panel 1400 comprises a soundabsorption coefficient of at least 0.5 as tested by ASTM C423-17.

In some examples, the wall substrate is cellulose free. In otherexamples, the open cell skin 1420 comprises an open surface area of atleast 10%, and wherein the wall panel 1400 comprises a noise reductioncoefficient of at least 0.85 as tested by ASTM C423-17. In certainconfigurations, the wall panel 1400 further comprises a porousdecorative layer disposed on the open cell skin 1420. In other examples,the flame retardant agent comprises expandable graphite particles ormagnesium hydroxide or both.

In certain examples, the open cell skin 1420 comprises a perforated filmwith an open surface area of at least 10%, and wherein the wall panelcomprises a noise reduction coefficient of at least 0.5 as tested byASTM C423-17. In some embodiments, the wall panel may comprise a closedcell skin disposed on a second surface of the porous core layer. Inother instances, the flame retardant agent is homogeneously dispersed inthe porous core layer. In some examples, the thermoplastic materialcomprises a polyolefin resin and the plurality of reinforcing fiberscomprise glass fibers or mineral fibers or both. In certain embodiments,a second wall panel can be coupled to the open cell skin 1420, whereinthe second wall panel is a porous wall panel.

In certain instances, any one or more of the articles described herein,e.g., those described in reference to FIGS. 1-10, can be configured as asiding to be attached to a building such as a residential home or acommercial building to absorb sound and to provide flame retardancy. Thesiding can be used, for example, to cover house wrap, sheathing or othermaterials commonly used on outer surfaces of a building. If desired, thesiding can be coupled to another substrate such as, for example, vinyl,concrete boards, wood siding, bricks or other substrates commonly placedon the outside of buildings. Referring to FIG. 15, a side view of asiding panel 1500 is shown. The panel 1500 may comprise any one of theLWRT articles described herein. As noted herein, the open cell skin ofthe siding is typically oriented toward a noise source to permit noiseabsorption. In some cases, the open cell skin of the siding faces towardan interior of a building, e.g., when noises from within the buildingare to be reduced, whereas in other instances the open cell skin of thesiding faces away from an interior of the building, e.g., when noisesfrom outside the building are to be reduced. If desired, two or moresiding panels can be sandwiched with one open cell skin facing into theinterior of the building and the open cell skin of the other wall panelfacing outward away from the interior of the building.

In some examples, the siding may be configured with a flame retardantand noise reducing layer can be coupled to a substrate 1530. Forexample, the flame retardant and noise reducing layer may comprise aporous core layer 1510 comprising a web of open celled structurescomprising a random arrangement of a plurality of reinforcing fibersheld together by a thermoplastic material, wherein the porous core layercomprises a flame retardant agent and an areal or basis weight of atleast 2000 gsm or at least 2100 gsm or at least 2200 gsm or at least2300 gsm or at least 2400 gsm or at least 2500 gsm, and an open cellskin 1520 coupled to a first surface of the porous core layer, whereinthe flame retardant layer comprises a flame spread index of less than 25and a smoke development index of less than 150 as tested by ASTM E84dated 2009, and wherein the flame retardant layer comprises a noisereduction coefficient of at least 0.5 as tested by ASTM C423-17. Thesubstrate 1530 can be configured with many different materialsincluding, but not limited to vinyl, wood, brick, concrete, etc. Forexample, a vinyl substrate can be coupled to a first surface of theflame retardant and noise reducing layer, and the siding can beconfigured to couple to a non-horizontal surface of a building to retainthe siding panel to the non-horizontal surface of the building.

In some instances, the siding panel further comprises a weather barrier,e.g., house wrap, a membrane, etc. coupled to a second surface of theflame retardant and noise reducing layer. In some embodiments, thesubstrate comprises a nailing flange to permit coupling of the siding tothe side of the building.

In certain examples, the open cell skin of the siding panel comprises anopen surface area of at least 10%, and wherein the siding comprises anoise reduction coefficient of at least 0.85 as tested by ASTM C423-17.In other examples, the flame retardant agent comprises expandablegraphite particles or magnesium hydroxide or both.

In some instances, the open cell skin of the siding panel comprises aperforated film with an open surface area of at least 10%, and whereinthe siding panel comprises a noise reduction coefficient of at least0.85 as tested by ASTM C423-17. In other examples, the siding panelfurther comprises a closed cell skin disposed on a second surface of theporous core layer. In some examples, the flame retardant agent ishomogeneously dispersed in the porous core layer. In other examples, thethermoplastic material comprises a polyolefin resin and the plurality ofreinforcing fibers comprise glass fibers or mineral fibers or both. Insome examples, the siding panel may further comprise a second sidingpanel comprising a second flame retardant and noise reducing layercoupled to a second substrate, wherein the flame retardant and noisereducing layer is configured to lock into the second flame retardant andnoise reducing layer when the substrate is coupled to the second vinylsubstrate, e.g., a butt joint, overlapping joint, etc. may exist wherethe two siding panels can horizontally lock into each other.

In certain instances, any one or more of the articles described herein,e.g., those described in reference to FIGS. 1-10, can be configured as aroofing panel to be attached to a building such as a residential home ora commercial building to absorb sound and to provide flame retardancy.The roofing panel can be used, for example, to cover an attic space,attach to roof trusses or cover a flat roof as commonly present incommercial buildings. If desired, the roofing panel can be coupled toanother substrate such as, for example, oriented strand board, plywood,or even solar cells that attach to a roof and function to cover theroof. Referring to FIG. 16, a perspective view of a roofing panel 1610attached to a house 1600 is shown. The roofing panel 1610 may compriseany one of the LWRT articles described herein. As noted herein, the opencell skin of the roofing panel is typically oriented toward a noisesource to permit noise absorption. In some cases, the open cell skin ofthe roofing panel faces toward an interior of an attic space, e.g., whennoises from within the attic space are to be reduced, whereas in otherinstances the open cell skin of the roofing panel faces away from aninterior of the attic space, e.g., when noises from outside the buildingare to be reduced. If desired, two or more roofing panel can besandwiched with one open cell skin facing into the interior of thebuilding and the open cell skin of the other roofing panel facingoutward away from the interior of the building.

In some examples, the roofing panel comprises a flame retardant andnoise reducing layer coupled to a roofing substrate. In certainexamples, the flame retardant and noise reducing layer comprises aporous core layer comprising a web of open celled structures comprisinga random arrangement of a plurality of reinforcing fibers held togetherby a thermoplastic material, wherein the porous core layer comprises aflame retardant agent and an areal or basis weight of at least 2000 gsmor at least 2100 gsm or at least 2200 gsm or at least 2300 gsm or atleast 2400 gsm or at least 2500 gsm, and an open cell skin coupled to afirst surface of the porous core layer, wherein the flame retardant andnoise reducing layer comprises a flame spread index of less than 25 anda smoke development index of less than 150 as tested by ASTM E84 dated2009, and wherein the flame retardant and noise reducing layer comprisesa noise reduction coefficient of at least 0.5 as tested by ASTM C423-17.The roofing panel may also comprise a roofing substrate coupled to afirst surface of the flame retardant and noise reducing layer andconfigured to couple to a roof of a building to retain the roofing panelto the roof.

In some examples, the roofing panel may comprise a weather barriercoupled to a second surface of the flame retardant and noise reducinglayer, e.g., a membrane, house wrap, tar paper, plastic film, etc. Inother instances, the roofing substrate comprises a cellulose-basedmaterial. In some examples, the open cell skin comprises an open surfacearea of at least 10%, and wherein the roofing panel comprises a noisereduction coefficient of at least 0.85 as tested by ASTM C423-17. Inother examples, the flame retardant agent comprises expandable graphiteparticles or magnesium hydroxide or both. In some examples, the opencell skin comprises a perforated film with an open surface area of atleast 10%, and wherein the roofing panel comprises a noise reductioncoefficient of at least 0.85 as tested by ASTM C423-17. In otherexamples, the roofing panel comprises a closed cell skin disposed on asecond surface of the porous core layer. In some instances, the flameretardant agent is homogeneously dispersed in the porous core layer. Inother examples, the thermoplastic material comprises a polyolefin resinand the plurality of reinforcing fibers comprise glass fibers or mineralfibers or both. In certain instances, the roofing panel comprises asecond roofing panel comprising a second flame retardant and noisereducing layer coupled to a second roofing substrate, wherein the flameretardant and noise reducing layer is configured to lock into the secondflame retardant and noise reducing layer when the roofing substrate ispositioned to overlap the second roofing substrate.

In certain configurations, any one or more of the articles describedherein, e.g., those described in reference to FIGS. 1-10, can beconfigured as a roofing shingle to be attached to a building such as aresidential home or a commercial building to absorb sound and to provideflame retardancy. The roofing shingle can be used, for example, to covera roof commonly present in residential and commercial buildings. Ifdesired, the roofing shingle can be coupled to another substrate suchas, for example, asphalt, ceramic, clay tile, aluminum, copper, woodsuch as cedar and other materials commonly found or used as roofingshingles Referring to FIG. 17, an exploded view of a roofing shingle1700 is shown. The roofing panel 1700 may comprise any one of the LWRTarticles described herein. As noted herein, the open cell skin of theroofing shingle is typically oriented toward a noise source to permitnoise absorption. In some cases, the open cell skin of the roofingshingle faces toward an interior of an attic space, e.g., when noisesfrom within the attic space are to be reduced, whereas in otherinstances the open cell skin of the roofing shingle faces away from aninterior of the attic space, e.g., when noises from outside the buildingare to be reduced. If desired, two or more roofing shingle can besandwiched with one open cell skin facing into the interior of thebuilding and the open cell skin of the other roofing panel facingoutward away from the interior of the building.

In certain examples, the roofing panel 1700 comprises a flame retardantand noise reducing layer comprising a porous core layer 1710 comprisinga web of open celled structures comprising a random arrangement of aplurality of reinforcing fibers held together by a thermoplasticmaterial, wherein the porous core layer comprises a flame retardantagent and an areal or basis weight of at least 2000 gsm or at least 2100gsm or at least 2200 gsm or at least 2300 gsm or at least 2400 gsm or atleast 2500 gsm, and an open cell skin 1720 coupled to a first surface ofthe porous core layer, wherein the flame retardant and noise reducinglayer comprises a flame spread index of less than 25 and a smokedevelopment index of less than 150 as tested by ASTM E84 dated 2009, andwherein the flame retardant and noise reducing layer comprises a noisereduction coefficient of at least 0.5 as tested by ASTM C423-17. Aweatherproof roofing shingle substrate 1730 can be coupled to a firstsurface of the flame retardant and noise reducing layer and configuredto couple to a roofing panel of a building to provide a weatherproof,flame retardant and noise reducing roofing shingle over the roofingpanel.

In certain instances, a weather barrier coupled to a second surface ofthe flame retardant and noise reducing layer. In other examples, theroofing shingle comprises asphalt. In some examples, the open cell skincomprises an open surface area of at least 10%, and wherein the roofingshingle comprises a noise reduction coefficient of at least 0.85 astested by ASTM C423-17. In certain examples, the flame retardant agentcomprises expandable graphite particles or magnesium hydroxide or both.In other examples, the open cell skin comprises a perforated film withan open surface area of at least 10%, and wherein the roofing shinglecomprises a noise reduction coefficient of at least 0.85 as tested byASTM C423-17. In some instances, the roofing shingle comprises a closedcell skin disposed on a second surface of the porous core layer. Inother examples, the flame retardant agent is homogeneously dispersed inthe porous core layer. In certain embodiments, the thermoplasticmaterial comprises a polyolefin resin and the plurality of reinforcingfibers comprise glass fibers or mineral fibers or both. In someexamples, the roofing shingle comprises a second roofing shinglecomprising a second flame retardant and noise reducing layer coupled toa second weatherproof roof shingle, wherein the flame retardant andnoise reducing layer is configured to lock into the second flameretardant and noise reducing layer when the weatherproof roofing shingleis positioned to overlap the second weatherproof roof shingle.

In certain configurations, any one or more of the articles describedherein, e.g., those described in reference to FIGS. 1-10, can beconfigured as an interior panel or wall of a recreational vehicle (RV)to absorb sound and to provide flame retardancy. The panel or wall canbe used, for example, to cover a skeleton structure on an interior sideof the recreational vehicle and may be coupled to foam or otherinsulation materials between the interior and exterior of therecreational vehicle. If desired, the RV interior panel can be coupledto another substrate such as, for example, a fabric, plastic, tile, etc.Referring to FIG. 18, a side view of a recreational vehicle 1800 isshown. The interior panel 1800 may comprise any one of the LWRT articlesdescribed herein. As noted herein, the open cell skin of the interiorpanel is typically oriented toward a noise source to permit noiseabsorption. In some cases, the open cell skin of the interior panelfaces toward an interior of the RV 1800, e.g., when noises from withinthe RV are to be reduced, whereas in other instances the open cell skinof the RV panel faces away from an interior of the RV 1800, e.g., whennoises from outside the RV 1800 are to be reduced. If desired, two ormore RV panels can be sandwiched with one open cell skin facing into theinterior of the RV and the open cell skin of the other RV panel facingoutward away from the interior of the RV.

In certain examples, a RV interior panel comprises a flame retardant andsound reducing layer comprising a porous core layer comprising a web ofopen celled structures comprising a random arrangement of a plurality ofreinforcing fibers held together by a thermoplastic material, whereinthe porous core layer comprises a flame retardant agent and an areal orbasis weight of at least 2000 gsm or at least 2100 gsm or at least 2200gsm or at least 2300 gsm or at least 2400 gsm or at least 2500 gsm, andan open cell skin coupled to a first surface of the porous core layer.In other instances, the RV interior panel comprises an interior wallsubstrate coupled to a second surface of the porous core layer, whereinthe recreational vehicle interior panel comprises a flame spread indexof less than 25 and a smoke development index of less than 150 as testedby ASTM E84 dated 2009, and wherein the recreational interior vehiclepanel comprises a noise reduction coefficient of at least 0.5 as testedby ASTM C423-17. In some examples, the interior wall substrate isconfigured as a decorative layer such as a fabric, a plastic, tile, woodor the like. In some instances, the open cell skin comprises an opensurface area of at least 10%, and wherein the recreational vehicleinterior panel comprises a noise reduction coefficient of at least 0.85as tested by ASTM C423-17. In other instances, the flame retardant agentcomprises expandable graphite particles or magnesium hydroxide or both.In some examples, the open cell skin comprises a perforated film with anopen surface area of at least 10%, and wherein the recreational vehicleinterior panel comprises a noise reduction coefficient of at least 0.85as tested by ASTM C423-17. In other examples, the RV interior panelcomprises a closed cell skin disposed on a second surface of the porouscore layer. In certain examples, the flame retardant agent ishomogeneously dispersed in the porous core layer. In some embodiments,the thermoplastic material comprises a polyolefin resin and theplurality of reinforcing fibers comprise glass fibers or mineral fibersor both. In additional instances, the RV panel comprises a second RVinterior panel comprising a second flame retardant and noise reducinglayer coupled to a second interior wall substrate, wherein the flameretardant and noise reducing layer is configured to lock into the secondflame retardant and noise reducing layer when the interior wallsubstrate is positioned to vertically overlap the second interior wallsubstrate at a first side of the RV interior panel. If desired, the RVpanel may comprise a third RV interior panel comprising a third flameretardant and noise reducing layer coupled to a third interior wallsubstrate, wherein the flame retardant and noise reducing layer isconfigured to lock into the third flame retardant and noise reducinglayer when the interior wall substrate is positioned to verticallyoverlap the third interior wall substrate at a second side of therecreational vehicle interior panel.

In certain configurations, any one or more of the articles describedherein, e.g., those described in reference to FIGS. 1-10, can beconfigured as an exterior panel or wall of a recreational vehicle (RV)to absorb sound and to provide flame retardancy. The panel or wall canbe used, for example, to cover a skeleton structure on an exterior sideof the recreational vehicle and may be coupled to foam or otherinsulation materials between the interior and exterior of therecreational vehicle. If desired, the RV exterior panel can be coupledto another substrate such as, for example, a metal, fiberglass, etc.Referring to FIG. 19, a side view of a recreational vehicle 1900 isshown that comprises an exterior panel 1910, which can be configured asany one of the LWRT articles described herein. As noted herein, the opencell skin of the exterior panel is typically oriented toward a noisesource to permit noise absorption. In some cases, the open cell skin ofthe exterior panel faces toward an interior of the RV 1900, e.g., whennoises from within the RV are to be reduced, whereas in other instancesthe open cell skin of the RV panel faces away from an interior of the RV1900, e.g., when noises from outside the RV 1900 are to be reduced. Ifdesired, two or more RV panels can be sandwiched with one open cell skinfacing into the interior of the RV and the open cell skin of the otherRV panel facing outward away from the interior of the RV.

In some examples, a RV exterior panel comprises a flame retardant andsound reducing layer comprising a porous core layer comprising a web ofopen celled structures comprising a random arrangement of a plurality ofreinforcing fibers held together by a thermoplastic material, whereinthe porous core layer comprises a flame retardant agent and an areal orbasis weight of at least 2000 gsm or at least 2100 gsm or at least 2200gsm or at least 2300 gsm or at least 2400 gsm or at least 2500 gsm, andan open cell skin coupled to a first surface of the porous core layer.The RV exterior panel may also comprise a weatherproof exterior wallsubstrate coupled to a second surface of the porous core layer, whereinthe recreational vehicle exterior panel comprises a flame spread indexof less than 25 and a smoke development index of less than 150 as testedby ASTM E84 dated 2009, and wherein the recreational exterior vehiclepanel comprises a noise reduction coefficient of at least 0.5 as testedby ASTM C423-17.

In certain configurations, the exterior wall substrate comprises glassfibers or is configured as a metal panel. In some examples, the opencell skin comprises a perforated film with an open surface area of atleast 10%, and wherein the recreational vehicle exterior panel comprisesa noise reduction coefficient of at least 0.85 as tested by ASTMC423-17. In other examples, the flame retardant agent comprisesexpandable graphite particles or magnesium hydroxide or both. In certainexamples, the open cell skin comprises a perforated film with an opensurface area of at least 10%, and wherein the recreational vehicleexterior panel comprises a noise reduction coefficient of at least 0.85as tested by ASTM C423-17. In some examples, the RV exterior panelcomprises a closed cell skin disposed on a second surface of the porouscore layer. In certain instances, the flame retardant agent ishomogeneously dispersed in the porous core layer. In some examples, thethermoplastic material comprises a polyolefin resin and the plurality ofreinforcing fibers comprise glass fibers or mineral fibers or both. Inother examples, the RV panel comprises a second RV exterior panelcomprising a flame retardant and noise reducing layer coupled to asecond exterior wall substrate, wherein the flame retardant and noisereducing layer is configured to lock into the second flame retardant andnoise reducing layer when the exterior wall substrate is positioned tooverlap the second exterior wall substrate at a first side of therecreational vehicle exterior panel. In additional examples, the RVexterior panel comprises a third recreational vehicle exterior panelcomprising a third flame retardant and noise reducing layer coupled to athird exterior wall substrate, wherein the flame retardant and noisereducing layer is configured to lock into the third flame retardant andnoise reducing layer when the exterior wall substrate is positioned tooverlap the third exterior wall substrate at a second side of therecreational vehicle exterior panel.

In certain configurations, any one or more of the articles describedherein, e.g., those described in reference to FIGS. 1-10, can beconfigured as an interior panel to absorb sound and to provide flameretardancy. For example, an interior building panel comprising a two- orthree-dimensional feature can be produced. The interior building panelcomprises a porous core layer comprising a web of open celled structurescomprising a random arrangement of a plurality of reinforcing fibersheld together by a thermoplastic material, wherein the porous core layercomprises a flame retardant agent and an areal or basis weight of atleast 2000 gsm or at least 2100 gsm or at least 2200 gsm or at least2300 gsm or at least 2400 gsm or at least 2500 gsm, and an open cellskin disposed on a first surface of the porous core layer, wherein theinterior building panel comprising the two- or three-dimensional featurecomprises a noise reduction coefficient of at least 0.5 as tested byASTM C423-17, and wherein the interior building panel comprising thetwo- or three-dimensional feature comprises a flame spread index of lessthan 25 and a smoke development index of less than 150 as tested by ASTME84 dated 2009. As noted herein and referring to FIG. 20, an interiorpanel 2000 is shown that comprises a two-dimensional feature including adepression 2010 and raised surface 2020. The ability of the panels toprovide complex shapes and surfaces is a substantial attribute. Suchshapes and multi-dimensional features can be molded into a desired shapeand used in interior applications including decorative wall panels.

In some examples, similar constructs can be used as interior trimapplications. For example, an interior trim comprising a flame retardantand noise reducing layer and an interior trim substrate can be used. Theflame retardant and noise reducing layer may comprise a porous corelayer comprising a web of open celled structures comprising a randomarrangement of a plurality of reinforcing fibers held together by athermoplastic material, wherein the porous core layer comprises a flameretardant agent and an areal or basis weight of at least 2000 gsm or atleast 2100 gsm or at least 2200 gsm or at least 2300 gsm or at least2400 gsm or at least 2500 gsm, and an open cell skin disposed on a firstsurface of the porous core layer, wherein the flame retardant and noisereducing layer comprises a noise reduction coefficient of at least 0.5as tested by ASTM C423-17, and wherein the flame retardant and noisereducing layer comprises a flame spread index of less than 25 and asmoke development index of less than 150 as tested by ASTM E84 dated2009. The interior trim substrate can be coupled to a first surface ofthe flame retardant and noise reducing layer and may comprise woods,PVC, vinyl, plastic, leather or other materials. A side viewillustration of a trim piece that can be used as baseboard trim is shownin FIG. 21. The trim piece 2100 comprises a trim substrate 2120 coupledto a flame retardant and noise reducing layer 2110. The trim piece 2100may be nailed or otherwise attached to a stud or wallboard as desired.The substrate 2120 faces outward and is viewable within a room. The trimpiece 2100 can be curved or may take two or three dimensional shapes asdesired.

In certain examples, a prepreg or core of the articles described hereincan be generally prepared using chopped glass fibers, a thermoplasticmaterial, a flame retardant material and open cell films and/or woven ornon-woven fabrics made with glass fibers or thermoplastic resin fiberssuch as, for example, polypropylene (PP), polybutylene terephthalate(PBT), polyethylene terephthalate (PET), polycarbonate (PC), a blend ofPC/PBT, or a blend of PC/PET. In some embodiments, a PP, a PBT, a PET, aPC/PET blend or a PC/PBT blend are can be used as the thermoplasticmaterial. To produce the prepreg or core, a thermoplastic material,reinforcing materials, flame retardant material(s) and/or otheradditives can be added or metered into a dispersing foam contained in anopen top mixing tank fitted with an impeller. Without wishing to bebound by any particular theory, the presence of trapped pockets of airof the foam can assist in dispersing the glass fibers, the thermoplasticmaterial and the flame retardant materials. In some examples, thedispersed mixture of glass and resin can be pumped to a head-box locatedabove a wire section of a paper machine via a distribution manifold. Thefoam, not the glass fiber, flame retardant material or thermoplastic,can then be removed as the dispersed mixture is provided to a movingwire screen using a vacuum, continuously producing a uniform, fibrouswet web. The wet web can be passed through a dryer at a suitabletemperature to reduce moisture content and to melt or soften thethermoplastic material. When the hot web exits the dryer, a surfacelayer such as, for example, an open cell film may be laminated onto theweb by passing the web of glass fiber, flame retardant material,thermoplastic material and open cell film through the nip of a set ofheated rollers. If desired, additional layers such as, for example, aclosed cell film, a non-woven and/or woven fabric layer, a surfacelayer, etc. may also be attached along with the open cell film to oneside or to both sides of the web to facilitate ease of handling theproduced composite. The composite can then be passed through tensionrolls and continuously cut (guillotined) into the desired size for laterforming into an end product article. Further information concerning thepreparation of such composites, including suitable materials andprocessing conditions used in forming such composites, are described,for example, in U.S. Pat. Nos. 6,923,494, 4,978,489, 4,944,843,4,964,935, 4,734,321, 5,053,449, 4,925,615, 5,609,966 and U.S. PatentApplication Publication Nos. US 2005/0082881, US2005/0228108, US2005/0217932, US 2005/0215698, US 2005/0164023, and US 2005/0161865.

In certain instances, a method of producing a composite articlecomprises combining a thermoplastic material, reinforcing fibers and aflame retardant material in a mixture to form an agitated aqueous foam.The foam is disposed onto a wire support, and the water is evacuated toform a web or open cell structure comprising the thermoplastic material,fibers and flame retardant materials. In some instances, the web is thenheated to a first temperature above the melting temperature of thethermoplastic material. In some instances, pressure can then be appliedto the web, e.g., using nip rollers or other devices, to provide athermoplastic composite sheet comprising the flame retardant materialdispersed in the web. An open cell film may then be disposed on theformed prepreg or core optionally with heating to bond the open cellfilm to the prepreg or core.

In certain instances, a method of producing a composite articlecomprises combining a thermoplastic material, reinforcing fibers and amixture of one or more of (1) EG materials and a (2) Group II or GroupIII metal hydroxide (such as MDH or ATH) in a mixture to form anagitated aqueous foam. The foam is disposed onto a wire support, and thewater is evacuated to form a web or open cell structure comprising thethermoplastic material, fibers and EG materials/group II or group IIImetal hydroxide materials. In some instances, the web is then heated toa first temperature above the melting temperature of the thermoplasticmaterial. If desired, the core may be compressed prior to fully forming.In some instances, pressure can then be applied to the web, e.g., usingnip rollers or other devices, to provide a thermoplastic composite sheetcomprising the flame retardant material from the EG materials/group IIor group III metal hydroxide materials dispersed in the web. An opencell film may then be disposed on the formed prepreg or core optionallywith heating to bond the open cell film to the prepreg or core.

In some embodiments, a composite article comprises a thermoplasticfiber-reinforced porous core layer and an open cell film disposed on atleast one surface of the porous core layer, the porous core layercomprising a web formed from a plurality of reinforcing fibers, a flameretardant material and a thermoplastic material, the composite articlecomprising an effective amount of the flame retardant material to meetClass A requirements as tested by ASTM E84 dated 2009 and to provide anoise reduction coefficient (NRC) of at least 0.50 as tested by ASTMC423-17. More particularly, the NRC may be at least 0.50 as tested byASTM C423-17.

The composite article can be used in various settings including, but notlimited to, office furniture, seating, etc. In some instances, thethermoplastic material comprises a polyolefin, the reinforcing fiberscomprise glass fibers and the flame retardant material comprises a groupII metal hydroxide or an EG material or both. In other examples, theglass fibers are present from about 30 to 60 weight percent, the flameretardant material is present from about 30 weight percent to about 50weight percent with the balance of the core layer comprising thethermoplastic material. The areal weight of the core is desirably atleast 2000 gsm or at least 2100 gsm or at least 2200 gsm or at least2300 gsm or at least 2400 gsm or at least 2500 gsm or more to enhancesound absorption. In some instances, an adhesive layer may be presentbetween the core layer and the open cell film. In certain embodiments,the article may comprise a second skin layer disposed on an oppositesurface of the core layer.

Certain specific examples are described to illustrate further some ofthe novel and useful aspects of the technology described herein.

Example 1

LWRT sheets were produced using a wet-lay method. The LWRT sheets werepolyolefin based, e.g., polypropylene based, and were reinforced usingchopped glass fibers. Polypropylene resin and glass fiber were mixed inwater and agitated into a uniform suspension. The suspension wasdeposited on a forming wire and the water was removed to form a webcomprising the polypropylene resin and the glass fibers. Furtherprocessing using heat melted the resin, and a solid composite core isformed after the web cools down to a temperature below the melting pointof the resin under pressure.

Example 2

LWRT sheets were formed similar to those produced in Example 1 but aflame retardant agent was added to the mixture of resin and choppedglass fibers. Two different flame retardant materials were usedincluding expandable graphite (EG) and magnesium hydroxide (MDH). Bothgrades meet the Class A requirements as tested by ASTM E84 method, andone grade meets SE-0 requirement as tested by SAE J369 method.

Example 3

Various materials were added to the core formed from Example 2subsequent to formation of the web of Example 2 but prior to final coreformation. Materials were applied to both sides of the web. Tables 1 and2 list various materials and additive present in certain tested LWRTarticles.

TABLE 1 Core FR Areal Addi- Density Surface Materials Added to Materialtive (gsm) the Core Control A None 2800 92 gsm film/scrim laminate onone side; 20 gsm scrim on other side Sample A1 MDH 2800 20 gsm scrim oneach side Sample A2 MDH 2800 88 gsm perforated film on one side; 20 gsmscrim on other side Sample A3 MDH 2800 92 gsm scrim/film laminate on oneside; 20 gsm scrim on other side

TABLE 2 Core FR Areal Addi- Density Surface Materials Added to Materialtive (gsm) the Core Control B None 1200 90 gsm scrim on one side; 20 gsmscrim on other side Sample B1 MDH 1200 20 gsm scrim on each side SampleB2 EG 1200 20 gsm scrim on each side Sample B3 EG 1200 90 gsm scrim onone side; 20 gsm scrim on other side

Loft is a property of LWRT cores that allows the thermo-formability ofLWRT materials. When an LWRT sheet is heated to a temperature above themelting point of the resin, the glass fibers in the LWRT sheet canspring back to a free standing status, which can result in a thicknessincrease of the composite sheet. The lofted LWRT can be further moldedto a desired thickness of the end-use application. The LWRT materialswere tested both with and without thermo-forming process. Taking a flat1200 gsm panel as an example, the LWRT material could be heated in anoven set at 204° C. for 4 minutes, and then compressed by a cold pressto the desired thickness.

Example 4

Physical properties, including areal density, ash content, as-producedthickness, and loft thickness, were measured using disks with a 99 mmdiameter. Two test standards were followed to test the acousticperformances. ASTM E1050 was followed to evaluate both groups ofmaterials, and the materials in Group A of Table 1 were also testedaccording to ASTM C423-17 method due to the potential usage for buildingand construction applications. SAE J369 and ASTM E84 methods werefollowed to conduct the flammability tests. SAE J369 is more popular inautomotive applications, whereas the performance tested by ASTM E84method gives more insight to the performance expected by officefurniture and building and construction industries. In addition,flexural strengths of the materials were also tested following ASTM D790or ISO 178 method.

Table 3 lists the measured physical properties of the various testedmaterials.

TABLE 3 Substrate Ash Pre-Loft Post-Loft Areal Density Content ThicknessThickness Material (gsm) (%) (mm) (mm) Control A N/A 57.5 13.1 14.5Sample A1 MDH 60.0 10.9 13.5 Sample A2 MDH 58.4 11.4 14.3 Sample A3 MDH58.9 11.9 13.4 Control B N/A 35.6 3.0 13.5 Sample B1 MDH 60 3.4 6.4Sample B2 EG 44.8 3.5 7.2 Sample B3 EG 43.2 3.6 7.3

Acoustic properties were measured for the Control A material using ASTME1050. FIG. 22 is a graph showing the sound absorption results.Acoustics properties were also measured on Sample A1 and Sample A2. FIG.23 is a graph showing those results. The materials were tested both withand without thermoforming process. The absorption coefficient does notshow dependence on the thermoforming process for either standard LWRTformulation or MDH formulations, when there is no surface laminates orwith just light weight scrim. The difference in Sample A2 before andafter thermoforming process materials is consistent with a minor surfaceopen area change during the thermoforming process. Generally, the soundabsorption performance is more determined by the combination of materialthickness, areal density and the open structure of surface materials.

Control B and Sample B3 were also considered for use in automotiveapplications, where more complicated part geometries are generallyrequired and the thermo-forming process would be necessary. Soundabsorption performances of Control B and Sample B3 were tested withoutthermo-forming and with thermo-forming to 4 mm and 6 mm as shown inFIGS. 24 and 25. Unlike the standard LWRT and MDH version LWRT, the EGgrade LWRT exhibits a different relationship between molding thicknessand absorption coefficient. A higher absorption coefficient is generallyachieved when an LWRT material is molded to a greater thickness, and itis believed the porosity determines, at least in part, the soundabsorption performance of the LWRT material. However, thenon-thermoformed EG grade material exhibited a higher sound absorptioncoefficient than the same material when it was molded to 4 mm thickness.This result is believed to be due to the layered structure of EGimproving the sound absorption of the material. The thermoformingprocess may cause some level of EG expansion in the heating process, andthat may be why the material molded at 4 mm shows lower acousticperformance than the material with a thickness around 3.6 mm beforethermo-forming. It is also noticed that significantly higher acousticperformances would be achieved in the higher frequencies, such as above4000 Hz.

Example 5

Due to the potential applications in building and construction industry,the noise reduction coefficient (NRC) and sound absorption average (SAA)numbers of Sample A1 and A2 were tested and summarized in Table 4.

TABLE 4 Material NRC SAA Sample A1 0.85 0.88 Sample A2 0.85 0.88

The samples have different surface materials facing the sound source inASTM C423-17 tests. Sample A1 had a light weight scrim surface layer,which is considered a high open area surface layer. In contrast, theperforated film used on Sample A2 only had an open area around 10%.Sample A1 and Sample A2 exhibited the same level of acousticperformance. Therefore, it is believed that a film with about 10%surface open area is suitable to achieve the same level of acousticperformance as an open structure light weight scrim.

Example 6

The flammability performance of Sample A1, A2, A3, B1, and B2 weretested using the ASTM E84 test standard. In the ASTM E84 standard, ClassA performance requires a Flame Spread Index (FSI) that is not largerthan 25 and a Smoke Development Index (SDI) that is not larger than 450.The materials were tested without the thermoforming process. All thetested materials meet Class A requirements as shown in Table 5.

TABLE 5 Material FSI SDI Sample A1 25 110 Sample A2 20 60 Sample A3 25105 Sample B1 20 90 Sample B2 15 35

The flammability depended more on the substrate formulation, and thesurface materials only affected the performance slightly. Between thetwo formulations, EG was considered a more effective FR additive, whileMDH provides more color options if required by the end use application.

Example 7

Control B and Sample B3 were also tested against SAE J369 method afterbeing thermoformed as these materials could be used for automotiveapplications. Sample B3 showed the capability to self-extinguish. Themolded material shows SE-0 level performances both as molded and afterbeing soaked with motor oil for 10 minutes. FIGS. 26A (top side) and 26B(bottom side) shows an example of the specimen after flammabilitytesting. The specimen was first soaked with 5W30 engine oil for 10minutes and drained vertically for 20 minutes. The specimen was lit fromthe engine oil rich edge. It self-extinguished and as shown in FIGS. 26Aand 26B, only minor damage occurred at the lighting edge.

Example 8

Flexural strength measurements of Control A and Sample A3 are comparedin FIG. 27, an FIG. 28 compares the flexural strength measurements ofControl B, Sample B1, and Sample B2. The materials were tested both inthe machine direction (MD) and cross-machine direction (CD). Themechanical strength of LWRT is more determined by the glass fiber andresin. Both kinds of additive are considered to generally lower themechanical strengths of the composites. Since EG is a more effective FRadditive, the flexural strength is less affected on the EG version LWRT,which could be the result of lower loading level of the additive.

When introducing elements of the examples disclosed herein, the articles“a,” “an,” “the” and “said” are intended to mean that there are one ormore of the elements. The terms “comprising,” “including” and “having”are intended to be open-ended and mean that there may be additionalelements other than the listed elements. It will be recognized by theperson of ordinary skill in the art, given the benefit of thisdisclosure, that various components of the examples can be interchangedor substituted with various components in other examples.

Although certain aspects, configurations, examples and embodiments havebeen described above, it will be recognized by the person of ordinaryskill in the art, given the benefit of this disclosure, that additions,substitutions, modifications, and alterations of the disclosedillustrative aspects, configurations, examples and embodiments arepossible.

1. A thermoplastic composite article comprising: a porous core layercomprising a web of open celled structures comprising a randomarrangement of a plurality of reinforcing fibers held together by athermoplastic material, wherein the porous core layer comprises a flameretardant agent and a basis weight of at least 2500 gsm; and an opencell skin disposed on a first surface of the porous core layer, whereinthe composite article comprises a noise reduction coefficient of atleast 0.5 as tested by ASTM C423-17, and wherein the composite articlecomprises a flame spread index of less than 25 and a smoke developmentindex of less than 150 as tested by ASTM E84 dated
 2009. 2. Thethermoplastic composite article of claim 1, wherein the flame retardantagent comprises expandable graphite particles.
 3. The thermoplasticcomposite article of claim 2, wherein the open cell skin comprises aperforated film with an open surface area of at least 10%, and whereinthe composite article comprises a noise reduction coefficient of atleast 0.85 as tested by ASTM C423-17.
 4. The thermoplastic compositearticle of claim 1, wherein the flame retardant agent comprisesmagnesium hydroxide.
 5. The thermoplastic composite article of claim 4,wherein the open cell skin comprises a perforated film with an opensurface area of at least 10%, and wherein the composite articlecomprises a noise reduction coefficient of at least 0.85 as tested byASTM C423-17.
 6. The thermoplastic composite article of claim 5, whereinthe thermoplastic material comprises a polyolefin resin.
 7. Thethermoplastic composite article of claim 6, wherein the plurality ofreinforcing fibers comprise glass fibers.
 8. The thermoplastic compositearticle of claim 7, further comprising a decorative layer disposed on asecond surface of the porous core layer.
 9. The thermoplastic compositearticle of claim 7, further comprising a closed cell skin disposed on asecond surface of the porous core layer.
 10. The thermoplastic compositearticle of claim 8, further comprising a decorative layer disposed onthe closed cell skin.
 11. A ceiling tile comprising: a porous core layercomprising a web of open celled structures comprising a randomarrangement of a plurality of reinforcing fibers held together by athermoplastic material, wherein the porous core layer comprises a flameretardant agent and a basis weight of at least 2500 gsm; and an opencell skin disposed on a first surface of the porous core layer, whereinthe ceiling tile comprises a noise reduction coefficient of at least 0.5as tested by ASTM C423-17, and wherein the ceiling tile comprises aflame spread index of less than 25 and a smoke development index of lessthan 150 as tested by ASTM E84 dated
 2009. 12. The ceiling tile of claim11, wherein the open cell skin comprises an open surface area of atleast 10%, and wherein the ceiling tile comprises a noise reductioncoefficient of at least 0.85 as tested by ASTM C423-17.
 13. The ceilingtile of claim 12, further comprising a porous decorative layer disposedon the open cell skin.
 14. The ceiling tile of claim 13, wherein theflame retardant agent comprises expandable graphite particles ormagnesium hydroxide or both.
 15. The ceiling tile of claim 14, whereinthe open cell skin comprises a perforated film with an open surface areaof at least 10%, and wherein the ceiling tile panel comprises a noisereduction coefficient of at least 0.85 as tested by ASTM C423-17. 16.The ceiling tile of claim 15, further comprising a closed cell skindisposed on a second surface of the porous core layer.
 17. The ceilingtile of claim 16, wherein the flame retardant agent is homogeneouslydispersed in the porous core layer.
 18. The ceiling tile of claim 17,wherein the thermoplastic material comprises a polyolefin resin.
 19. Theceiling tile of claim 18, wherein the plurality of reinforcing fiberscomprise glass fibers or mineral fibers or both.
 20. The ceiling tile ofclaim 18, wherein the porous core layer further comprises a clay.21-102. (canceled)